Updated 2010
Joseph L. Coffman
www.xcellus.net
www.efficiency100.com
OBJECTIVE
My goal is to develop your operational management system and successfully lead your organization to execution excellence through continual improvement of business processes. My goal is to build internal capability and adaptability to the ever-changing world conditions, achieve sustainable results, and continually increase efficiency and cost effectiveness. I am the results-oriented leader your company needs to develop your culturally diverse environment.
PROFILE
• 13+ years experience as professional manager
• Holistic approach to Operations, Continual Improvement and Lean Six Sigma activities
• Integration of all employees into the culture of continual improvement
• Responsible for creation and rebirth of Lean Six Sigma initiatives in a variety of industries
• Execution of policy deployment and translation of objectives to all levels of workforce
• College instructor of Six Sigma and Project Management principles
• Organized, highly motivated problem solver
• Facilitation of project scoring and selection matrix for executive prioritization and decision making
• Future-minded strategic planning
• Mentor and leader for management and production associates
• Able to win respect of factory floor associates, technical staff, and executives alike
• Negotiation experience during program execution with contractors and vendors
RELEVANT EXPERIENCE & ACCOMPLISHMENTS
• Successful deployment of Operations Management and Lean Production Systems, a.k.a. Toyota Production Systems at medium to large manufacturing organizations (1000 – 7000 employees)
• Achieved results consistently
• Align employees with business objectives and strategies through annual strategic policy deployment
• Managed activities for Lean Coordinators, engineers, production managers and quality personnel during Operations daily and weekly SQDEC roll-up meetings
• Facilitated Visual Factory development and deployment at various manufacturing locations and drove the management routines to support it
• Driver of Standardized Work using Job Instruction (JI) training with TWI, making problems visible, kaizen improvements
• Driver of Maynard Operation Sequence Technique (MOST) for standard labor requirements at large production facilities
Management/Supervision
• Directed project management activities for more than 100 employees
• Managed P&L > $100M
• Develop and manage performance management objectives
• Train, supervise and evaluate staff, coach improvement skills
• Upgrade technical workforce abilities by introducing Green Belt and PM skills into their performance objectives
• Establish project management programs at multiple companies
• Successfully established Lean Production System and Six Sigma process improvement programs at multiple companies growing the departments to hundreds Black and Green Belts in total
EMPLOYMENT
Director of Continuous Improvement, Operations - 2008-present
Alliant Techsystems (ATK) – Independence, MO & Radford, VA
• Leader of the Performance Enterprise System and Reliability Engineering
• Accountable for bottom-line results and substantial EBIT challenges
• Responsible for policy deployment and strategic objective development
• Leader of Lean Production or Toyota Production System deployment and associated activities
• Implementation of the Visual Factory across entire operational facility, which includes 10 distinct plants and 1300+ employees, with 900+ direct labor
• Responsible for Standard Work implementation and driver of Maynard Operation Sequence Technique (MOST) at facility with development of many engineers as certified MOST analysts
• Leader of Six Sigma activities, including program development, training activities, project leader development, and operational deployment
• Creation of Kaizen activities system for support of the Visual Factory
Managing Director - 2007-present
Process Improvement, LLC (http://www.efficiency100.com/) - Bradenton, FL
• Principle consultant and Operational Management System deployment leader for team of 6 consultants in project activities, training initiatives, and Lean Six Sigma project improvement activities
• Generate new business opportunities, proposal development and contract execution
• Win support and develop commitment from client executive leadership for operational management activities, process improvements, training and project concept and initiation
Manager - Master Black Belt - 2004-2007
Smith and Nephew, Medical Device Manufacturer – Largo, FL
• Operational Excellence leadership
• Responsible for culture change throughout Largo Operations – Six Sigma and Project Management Program development in a cGMP environment
• Led Lean Production and Six Sigma deployment activities at Largo and additional US locations – also strategic partner locations
• Managed more than thirty Black Belts and Green Belts in their improvement project activities
• Created project tracking and updating system to help management receive project status reports and to help manage the multi-project landscape as well as the ever-present resource capacity issues
• Spearheaded an initiative to change the operational efficiency throughout Largo Operations. The $200k project to develop and install a shop floor OEE system was a success and shifted the entire organization operational efficiency greater than 5%
• Conducted 5 waves of Six Sigma Training which include: In-house Green & Black Belts, outside vendors, Green, Black Belts, & MBB’s in Smith & Nephew Orthopedics Division, and NuCryst Pharmaceuticals in Canada. Additionally, the entire management team received Six Sigma DMAIC overview training (Yellow Belt) in bi-weekly sessions of 3 hours each
Black Belt - 1999-2004
IMC Phosphates, Chemical Manufacturing – Mulberry, FL
• Project Manager of various Six Sigma projects in plant operations to increase production and efficiencies and to reduce production variability, defects, downtime, and waste - Completed six projects totaling more than $5M in savings or revenue
• Coached and managed multiple Action Workout project teams to affect process change and achieve bottom-line results in sixty days or less – Quick, schedule-driven improvement projects
• Developed and delivered Six Sigma Green Belt training program
• As part of the first Six Sigma project at IMC, initiated, developed business case, and successfully completed an automatic reagent blending, batching, and delivery system - Reduction in variability of the blended reagent changed from a process capability resulting in 2.5% in-spec product to 99.999% in-spec product
• Successfully managed four Advanced Process Control development projects. The $8M projects spanned three years of implementation
Process Control Engineer - 1998-1999
Boeing – Kennedy Space Center, FL
• Managed development and implementation project for Advanced Process Control strategies for predicting process pressures and flows of liquid hydrogen fuel and liquid oxygen oxidizer during the pre-launch filling of the Space Shuttle’s external tank
• Implemented automatic PLC-based checkout procedures for a high-pressure system - System reduced the time required to pressure check the system from five days to several hours
• Developed application procedures for the testing the system hardware for the engine control unit (ECU) of the Delta-IV rocket
Engineer, and Intern and Fellowship - 1996-1998
NASA – Kennedy Space Center, FL
• As Engineer, developed Advanced Process Control strategies for use during the fuel and oxidizer loading of the Space Shuttle’s external tank
• Developed the engine-start sequence for the Delta IV rocket
• As part of my Master’s thesis, and through internships and fellowships, developed various control and predictive models for use during the propellant loading phases before liftoff.
EDUCATION
MBA Current GPA: 3.5/4.0
• Colorado State University - Fort Collins, CO
M.S., Chemical Engineering 1998 GPA: 3.87/4.0
• Florida Institute of Technology - Melbourne, FL
B.S., Chemical Engineering 1997 GPA: 3.54/4.0
• Florida Institute of Technology - Melbourne, FL
CERTIFICATIONS
Six Sigma Master Black Belt Certification...........................................BMG
Lean Master..............................................................................................SME
Project Management Professional (PMP) Certification....................PMI
Six Sigma Black Belt Certification .......................................................ASQ, GE & BMG
Maynard Operation Sequence Technique (MOST) Certification....Accenture
Certified Maintenance & Reliability Professional..............................SMRP
Stellar Service Facilitator Certification.................................................Achieve Global
Action Workout Coach Certification .....................................................Leap Technologies
HONORS & AWARDS
Magna Cum Laude - BS ChE
Tau Beta Pi - The National Engineering Honor Society
Sharing Space Technology - NASA
ADDITIONAL SKILLS
Leadership, Team and Meeting facilitation, Cost/Benefit Analysis, Problem Solving, Oral and Written Communication,
College Instructor in Lean Six Sigma, Project Management, Statistics & Minitab
International trainer of: Project Management (PMP), cGMP, Lean Six Sigma and other process improvement methodologies. MS Project, Minitab statistical software, Visio, Microsoft Excel, Word, PowerPoint, Access, process mapping, Work Breakdown Structures, Resource Breakdown Structures
AFFILIATIONS
ASQ - The American Society for Quality
PMI - The Project Management Institute
Tau Beta Pi - The National Engineering Honor Society