Star War Episode I Toy Premiums: 64,000,000 units over 28 designs Worldwide for: KFC, Taco Bell, Pizza Hut.
One of the most complex designs for fast food premium toys became more complex when a collectable gift box with taper-proof seal was offered after tool start for the "WOW" factor. The first time a collectable gift box was used this way, it became a challenge to optimize size for each unique shaped toy while minimizing cube size to save the client's freight cost and pass drop and transit testing. The box was designed with printed graphics inside and out for collectability to build 2 murals from all styles collected. This fast-cycle project was completed on-time (no air frt), near budget (gift box extra) and safely with the proper "SPEED BUMPS" in the process for design evaluations, pre-production research testing and during-production testing using production process flowchart and pareto charts to control the factories and supply chains. The success of this mission is due to the talent and dedication of the Hong Kong office staff.
Ensured that millions of sidewalk chalk and crayons shipped to clients were lead-free by carefully evaluating suppliers and their quality systems, which resulted in sourcing a reliable Southeast Asian manufacturer in 1993, thus saving the company and our clients from CPSC's operation dubbed "Dead Lead" during 1993.
Key Success Factors for Sourcing 1) Planning with detailed Milestone Schedules. 2) Precise communications with frequent follow-up and monitoring. 3) Leveraging the manufacturer and transparency
Key Success Factors for New Product Development 1) Planning with detailed Milestone Schedules. 2) Detailed production specifications with process flowcharts. 3) Bill of material cost sheet with cost factors, labor rates and flowchart hours.
On-boarding New Factories starts with:
1) Factory self-audit questionnaire and profile with workshop photos. 2) Factory visit to survey workshops and verify information given in questionnaire and profile. 3) Trial order for factory to learn order process requirements and implement corrective actions as needed.
Project Milestone Schedules
Concept Stage: customer needs & expectations convert to product function, features and regulatory standards. Feasibility Stage:verify technology and resources to the design, produce and market.
Project Turnover from Upstream (art) to Downstream (parts).
Planning Stage:careful, realistic product business planning compliant with product regulatory standards. Design Stage: detail design specifications for tool let.
Prototype Stage: (EP-Engineering Pilot) 1st Shot, Fit & Function, Line tool let, research testing, test to failure to create test standards with force diagrams. Pilot Stage:(FEP-Final Engineering Pilot) Pilot Line tooling, pre-production testing and Quality Assurance Plan. Validation Stage: (PP-Production Pilot) Pilot Assembly & Packout, final pre-pro testing Production Stage: (PS-Production Start) Ramp-up Production, dupro testing
Manufacturing, Sourcing, Product Development, Quality Assurance, Regulatory Compliance, Overseas work assignments with extensive travel to industrial clusters throughout Asia; including within 29 of China's 34 Province-Level Divisions.
Consumer Product Importers, Greater NYC, USA
Consumer Product Importers, PRC
Applause/Dakin Hong Kong, SAR Sr. Director Strategic Alliances Asia Operations and Premium Product Engineering
Custom Fast-Food Toy Premium Manufacturer,Southern California, USA Sr. Project Engineer: Promotional premium gifts and toys. Sr. Cost Engineer: Developed a Global Strategic Costing System
Plastics Manufacturing Technology College of DuPage
Predetermined Methods-Time Data (PMD) Mattel Industrial Engineering
Compliance, Regulatory Affairs, Corporate Social Responsibility and NGO (Non-Government Organization) Cooperation.
"To rely on rustics and not prepare is the greatest of omission of duty, to be prepared before hand for any contingency is the greatest of virtues." Sun Tzu
"Product development has 3 stages: 1) System design 2) Parameter design 3) Tolerance design." Genichi Taguchi "An important feature of a good quality program is that it controls quality at the source." Armand V. Feigenbaum
"Believe none of what you hear,and only half or what you see." Benjamin Franklin "Quality control begins and ends with education." Kaoru Ishikawa "Quality is everyone's responsibility." W. Edwards Deming "Quality is fitness for use." Joseph M. Juran