ed's resume.html

Edward Eugene Baccus

873 Eden Farms Circle     Westminster, Maryland 21157-2932

(410) 871- 9278   email: ed8256@hotmail.com

EDUCATION: MBA/Management Science and Operations Management – Wright State University - 1992

                                 BSB/Accounting and Finance – Wright State University - 1988                                               

                                   AS/Business Administration  - Sinclair Community College - 1984

SUMMARY:  Expert in lean production system implementation, quality and productivity improvement.

• Progressed through the following positions: Production Operator, Journeyman Toolmaker, Plant Statistician, Quality Engineer, Production Supervisor, Skilled Trades Supervisor, Manufacturing General Supervisor, Sr. Quality/Reliability Engineer, Sr. Lean Manufacturing Systems Engineer, Assembly Plant Quality Director, Assembly Plant Area Manager, General Motors Manufacturing Executive, Corporate Quality Director.

            Manufacturing expertise includes:

• Trained in lean manufacturing and the Toyota Production System at Akebono Brake Company in Japan; Implemented a new plant start up using lean manufacturing techniques resulting in world class quality levels; Excellent communicator; Data driven; Leads using teamwork and vision. 

            Quality expertise includes:

• Expert in quality systems and statistical methods having had a personal and professional relationship with Dr. W. Edwards Deming; facilitated a Deming Seminar December, 1990; Graduate of The Juran Institute; Graduate of The University of Tennessee, Knoxville Institute for Productivity through Quality; Trained in many problem solving methodologies including Taguchi, Shainin and Kepner Tregoe; Designed and implemented quality systems leading to QS9000 and ISO 9002 registration.

EXPERIENCE:   

6/2003 to 9/2003 Florida Production Engineering

Corporate Quality Director

Corporate Quality Director responsible for three tier one automotive plants

 ·        Established common quality system for multiple plants

• Established corrective action process to resolve product quality issues resulting in immediate 35% savings in scrap of major new product start-up using practical problem solving
• Re-organized quality department of lead corporate plant…establishing quality ethic changing inspection culture to one of problem solving, root cause analysis, error proofing and quality engineering

2001 – 7/2003   World Class Business Associates

ASSOCIATE   Consulting firm specializing in lean manufacturing and quality improvement methods.  
Specialist in executive leadership development, lean manufacturing, quality improvement and problem solving; Assisted in the forming and defining of the firm and its objectives; Assisted in developing the philosophy and foundations for the company.

 1998 – 2001        General Motors Truck Group

ASSEMBLY PLANT AREA MANAGER  (Baltimore Assembly, Baltimore, MD) 1999 - 2001
Manufacturing executive of automotive paint shop of three hundred salaried and hourly employees. Achieved JD Power Initial Quality Survey 2 Wave 1 rating as "most improved" in North America. Reduced repair loop time from thirty minutes to two minutes yielding significant ongoing savings. Reduced non-scheduled overtime using line balance methods based on reduction of buffers and lean manufacturing concepts.

ASSEMBLY PLANT QUALITY DIRECTOR  (Arlington Assembly, Arlington, TX) 1998 - 1999
Quality Director of 3.7 million square foot automotive assembly plant building General Motors Trucks including the Cadillac Escalade, GMC YUKON DENALI and quarter-ton units; Led implementation and execution of plant quality systems and initiatives; Designed and had built a tool to rework wheel weights correcting a no build situation and resulting in Cadillac Escalades and GMC Denalis being put back in production schedule. 

Led the quality organization consisting of approximately 125 employees including: hourly torque and TRIPTS monitors, CARE (Customer Acceptance /Reliability Evaluation) line inspectors and the salaried organization including: Reliability/Quality Engineers, Squeak and Rattle Engineers, Quality Planner, ISO Coordinator, Supplier Quality Engineers, Process Control Managers, General Supervisors of Inspection, General Supervisor of Quality, Department Coordinator and support staff.  

Coordinated implementation of Pre-CARE activities, ANDON and Verification Stations to support Competitive Manufacturing Strategies and a common Quality System; Instrumental in designing a fully integrated corrective action process that included ISO 9002 Internal Audits that became the model for integrated management review.

1975 – 1998 DELPHI Chassis System – Division of Delphi Automotive Systems, Dayton, OH
 DELPHI LEAN MANUFACTURING SYSTEMS ENGINEER   1995 - 1998
Quality and Lean Manufacturing Expert responsible for all Advanced Product Quality Planning (APQP), Production Part Approval Process (PPAP) and QS 9000 requirements during the Home Ave./Vandalia Operations conversion from mass to lean manufacturing. Developed and implemented the quality system for a $10 million new plant start up and lean manufacturing project; coordinated quality requirements through APQP, system documentation, process design and start of production.  Managed and approved over 80 PPAP submissions while the organization achieved QS 9000 Certification;

SENIOR QUALITY/RELIABILITY ENGINEER   1994 – 1995
Implemented Quality Process Monitoring System to address quality system deficiencies and quality spills; This system led to the organization being QS 9000 certified; a multi-plant achievement. 

GENERAL SUPERVISOR MANUFACTURING   1993 – 1994
Managed the $10,000,000 strut mount business unit at the Dayton location; the workforce consisted of 125 salaried and hourly employees.  Responsibilities included manufacturing, quality, schedule attainment, housekeeping and safety; coordinated A.T. Kearney uptime initiative resulting in 123% productivity improvement in the molding and assembly areas; established the model for workplace organization leading to safety improvements and a 25% reduction of in house inventory; championed pull system implementation with supplier and customer Kanban.

LEAD SUPERVISOR TOOL & DIE ROOM and STAMPING DEPARTMENTS   1992 – 1993
Managed Tool & Die Room with 36 skilled employees including Tool & Die Makers, Machinists, Precision Grinders, CNC Operators, Machine Repairmen/Tool Room Welder;  supervised Stamping/Punch Press Dept.  Instituted first Preventive Maintenance Program for injection molds as a corrective action to a chronic quality problem.  Increased mold repair throughput 33% through the mold section of the tool room; established methods for in-press transfer mold date stamping and repair methods leading to improved plant performance in schedule attainment and product quality.

SUPERVISOR MANUFACTURING    1991 – 1992
Supervised manufacturing operations across the hydraulic (new technology) mount plant. Processes included robotic assembly lines with complex internal components and configurations (patent protected); transfer molding of rubber inserts; direct supervision averaged sixty hourly employees; labor efficiencies improved 16% in assembly and 20% in the stamping department due to problem solving and improvement activities. Nominated for a peer recognition award in the area of Positive Leadership.

Started the methodology for Kanban scheduling between transfer molding and robotic assembly departments that led to improved schedule attainment and minimized in process inventory;

PLANT STATISTICIAN & QUALITY ENGINEER    1989 – 1991
Worked with problem solving teams to diagnose and solve quality problems. Authored and taught courses on process capability and statistical process control; Named to the Corporate Statistical Review Committee established at General Motors by William Scherkenbach leading to internship with Dr. W. Edwards Deming. Solved chronic quality and throughput problems leading to 33% improvement in throughput and substantial reduction in scrap rates throughout the plant.

JOURNEYMAN TOOLMAKER    1975 – 1989
Served skilled trades apprenticeship; Built tools/dies/fixtures/jigs as required per blueprint and/or verbal instructions.

PRODUCTION OPERATOR   1974 FRIGIDAIRE Division of General Motors, Moraine, Ohio
Performed assembly line work as required; worked assembly lines producing washers, dryers and refrigerators.

SPECIALIZED TRAINING:

Certified in Lean Manufacturing, First Time Quality Improvement and Internal Consulting by  Kaizen Institute of America, Inc.

Worldwide Flow College Advanced Mixed-Model Workshop & Demand Flow Technology & Business

Strategy. Series 400 and 700, J-I-T Institute of Technology, Inc.                       

Certified QS 9000 Internal Quality Auditor, Registration Number: R141 Certificate Number:  20381170

Quality Engineering/Reliability Engineering/ and Experimental Design

Statistical Process Control and Productivity Methods
Graduate of The Juran Institute, Inc.

Graduate of The University of Tennessee, Knoxville Institute for Productivity through Quality

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