Richard Ray - QA - CI Resume

RICHARD J.
RAY
15 Founders Way Downingtown, PA 19335
[email protected] (484) 947-9523
Director - Quality Assurance / Continuous Improvement

Lean - Continuous Improvement / ISO 9001: 2000 / ASQ CSSBB Supplier Qualification / SPC / Product Development / Quality Audits
Utilize my extensive experience in Operational and Business Process Improvement, along with ISO 9001:2000 quality management systems, and Six Sigma methodology to assist a manufacturing organization in eliminating waste and achieving a continuous and measurable improvement, with a customer driven focus on reduction of variability between multi-line/plant operations and improved process capability. Project experience in 22 plants in 6 countries. Results oriented but Process focused. PROFESSIONAL EXPERIENCE CERTAINTEED CORPORATION, Valley Forge, PA
Insulation Group $750 million manufacturer of fiber glass insulation
2000 - 2008
Group Manager of Quality Assurance and Continuous Improvement - (2007 2008)

Developed and directed the quality assurance program for CertainTeeds Insulation Group. Directed methods for improving product quality and design, and manufacturing processes, with an emphasis on process capability and Lean Six Sigma. Qualified and monitored the performance of suppliers. Five plant QC Mgrs. had reporting relationship to me. Directed quality initiatives to support significant process and glass chemistry changes - Through process capability study, was able to adjust glass composition allowing for a $750K/ year cost reduction. Implemented quality standards at CertainTeed through adoption of warehousing changes - Insulation susceptible to shelf life was being warehoused on LIFO basis, leading to product loss. Analyzed current warehousing and implemented plan to store susceptible products in new configuration, with no loss of warehousing space, allowing for conversion to FIFO inventory.
Manager Design for Six Sigma and Quality Assurance (2002 2007)
Managed the technology transfer to Operations of new products, product redesigns, and new process implementations, keeping the Voice of the Customer in the forefront of decisions. Implemented SPC to the quality reporting system to better judge the performance against key quality parameters. Five plant QC Mgrs. had reporting relationship to me.
Increased operating profits by $1M and line productivity by 1.5%, while reducing quality complaints by 40%. - Worlds largest fiber glass insulation line had history of quality issues during summer months. Line caused over 50% of entire Divisions QC complaints. Led Six Sigma team to analyze production line, completing over 100 action items. Reduced complaints by 40%, while increasing line productivity 1.5% and profits $1M annually
Refined data analysis technique, saving 8M pounds of raw materials and improving earnings by $5M / year. - Former thermal test technique was underestimating insulations thermal performance. Analyzed data and identified the opportunity to decrease test time by one hour. - Reduced weight of some products, saving 8M pounds of glass. Improved operating earnings by $5M per year through utilization of saved materials. - Reduced testing by 5K hours per year and elimination of 20% invalid test data.
Reduced Customer Service Complaints by 80% - Order Fulfillment Lean Sigma Project - On average, reduced the hold time, abandoned calls, and customer service complaints by 80%. - Inventory accuracy improved with 50% reduction in stock-outs. - On quantity, on time production compliance improved 30 percentage points. - Reduction in late release of orders from 7% to less than 1%.
RICHARD RAY
PAGE TWO
Manager of Residential Technical Services (2000 2002)

Provided technical marketing & services support to Marketing, Sales, and Customers. Participated in technical associations and CertainTeed product development. Served as the Global Technical Coordinator for Building Insulation at CertainTeed / Saint-Gobain Isover. Named Insulation Contractors Association of America (ICAA) Man of the Year - 2002
Developed and wrote the ICAA Technical Bulletin on Vapor Retarders.
JOHNS MANVILLE INTERNATIONAL, INC., Denver, CO $2.2 billion international manufacturer of building materials.
1974 2000
Section Manager Product Development - (1985 2000)

Led team of up to 6 engineers and 3 technicians on all aspects of product development, technical service, and cost reductions for the Building Insulation Division, with 1999 sales of $500 million. Acted as liaison between Marketing and Manufacturing. Handled all Building Science issues for Division. Initial Product Manager for ComfortTherm, acting Commercial Marketing Manager. Technical Marketing.
Developing New Technology - Project Manager, development of Formaldehyde Free fiber glass insulation - Team developed the binder chemistry and specialized curing capabilities. - Entire Division has converted to this white, formaldehyde free binder. Implementing New Technology Project and Product Manager for ComfortTherm a fiber glass insulation. , - Led matrix organization of 25 people for 2 years with capital expenditure budget of $6 million. - As Product Manager, expanded product line from 2 products to 20 and from 1 plant to 3 plants. - $15M in sales to the retail market. Developing New Products Directed product design and development of ClimatePropremium loose-fill - Resulting in re-opening a previously closed plant in Indiana - Production rate of 325,000 lbs. per day for Division with annual sales of $45 million. - Developed test methods and design methodology that is now basis for ASTM C1630 and C1574 Std. Guides. Cost Reductions - Conducted freight optimization trials at 4 US plants. Results led to product and packaging redesigns and reducing costs by $1.6 million annually. - Through continuous improvements and statistical modeling of product performance, reduced cost by $1M annually from Divisions newest production line.
Sr. Research Engineer (1974-1985) Led Product Development efforts for air handling, equipment, commercial, marine, appliance, and building insulation product lines. - Developed John Manvilles first retail roll product improving packaging techniques now a $100 million market with fastest growing segment, ComfortTherm. Developed Lina-CousticDuct Liner sold successfully for 20 years. Developed John Manvilles first insulation for self-cleaning ovens, requiring very low, yet uniform, binder content, through implementation of equipment with tighter process control than previously available.
Current Work and Activities

Target Team Member 2010 Present U.S. Census Bureau Enumerator during 2010 Census (rated in top 5% of 1600 enumerators) 2010 American Society for Quality Certified Six Sigma Black Belt 2010 Master Certificate in Six Sigma Villanova University 2009
EDUCATION
B.S. - Industrial Engineering, University of Toledo, 1974

Outstanding Industrial Engineering Student Scholarship, 1973, 1974; Speaker of Student Senate; Chairman, Budget Review Committee $2.5 million budget; President, Theta Chi Fraternity and Blue Key Mens Honorary Fraternity; Member, Alpha Pi Mu, National Industrial Engineering Honor Society
9 Patents issued, 1 application pending

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RICHARD J.

[email protected] (484) 947-9523

Director - Quality Assurance / Continuous Improvement

Group Manager of Quality Assurance and Continuous Improvement - (2007 2008)

Manager of Residential Technical Services (2000 2002)

Developed and wrote the ICAA Technical Bulletin on Vapor Retarders.

Section Manager Product Development - (1985 2000)

Current Work and Activities

B.S. - Industrial Engineering, University of Toledo, 1974

9 Patents issued, 1 application pending

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