Manufacturing Professional specialized in Cycle-Time Reduction with Sourcing and NPD that meets global standards for product and factory. Experience includes: - Fast-Food Toy Premiums, Fashion Handbags, Small Leather Good's, Laptop/Camera/Phones Bags/Cases, Consumer Electronics, Hometextiles, Home Decor, Lighting, Gifts, Cosmetics, Medical Devices and Toys. -Onboarding OEM suppliers in major industrial clusters (from Guangzhou-Wenzhou-Yangzhou-Qingdao-Tianjin-Chengdu) in China 2001-2008. -Established Northern China bases of operation and hired/trained staff.
-Training PRC staff on international sourcing ethical standards, quality systems workshop audits and fast-cycle new product development. -Working knowledge of workshop ethical/social standards and quality systems audits, product testing & inspection and product standards. -Develop product safety and liability prevention protocols including an incident database. -Manufacturing, product cost engineering, product safety, design evaluations, regulatory affairs, quality assurance, product performance and workshop social responsibility standards for light industry manufacturing of OEM fast moving consumer goods (FMCG). -Coaching PRC staff on fast-cycle new product development with Custom Retail/Private Label orders.
Project Highlights
1999 Star War Episode 1 Toy Premiums Tricon 64,000,000 units Worldwide: 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 collectibility 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 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 1993-1994.
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 with workshop photos. 2) Factory visit to survey workshops and verify information given in questionnaire. 3) Trial order for factory to learn order process requirements and implement corrective actions as needed.
Project Milestone Schedules
Strategic Level:
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.
Tactical Level:
Prototype Stage: (EP-Engineering Pilot) 1st Shot, Fit & Function, Line tool let, test design force diagrams Pilot Stage: (FEP-Final Engineering Pilot) Pilot Line tooling, pre-production testing and QAP Validation Stage: (PP-Production Pilot) Pilot Assembly & Packout, final pre-pro testing Production Stage: (PS-Production Start) Ramp-up Production, dupro testing
Business experience: Global Sourcing and New Product Development '11-Current Director Product Evaluation, Compliance and QA '09-11 Director Global Sourcing Northern China '05-08 Director Quality Assurance Greater China '01-05 Applause/Dakin 'HK/China Sr. Director Strategic Alliances Asia Ops & Product Engineering Strottman International'CA USA Sr. Project Engineer: Promotional premium gifts and toys. Sr. Cost Engineer: Developed a Global Strategic Costing System Mattel Toys 'CA,USA Product Safety, Integrity Engineering, Operations Finance, Brand Analysis: -Brand Analysis Financial Analyst: Global Strategic Costing Systems -Operations Financial Analyst Cost Engineering Manual. -Product Integrity & Safety Engineering: Marshall Bravestarr Design Evaluations. Service Plastics (formerly CTS) 'Chicagoland, USA Manufacturing Engineer: Matsushita (MIC), Panasonic/QuasarTV housings.
"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 "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
