Six Sigma Lean & Quality Management

BIO

Ms.C.Ethier, P.Eng. MSME

CatherineEthier was responsible for managing the Quality Management Program and the Six Sigma Lean Projects at a Fortune 500 company, where she received the Key Contributor Award for performance excellence. Catherine was trained by SHINGIJUTSU-Japan on the practical application of the Toyota Production System (TPS).

CatherineEthier is teaching Lean Workshops for Professional Engineers Ontario and ASQ related to Lean Fundamentals and Lean Deployment. Lean is a discipline focused on eliminating waste (muda - Japanese) and variability throughout the supply chain (large logistics hubs, office, finance, manufacturing processes, customer and supplier system integration, JIT, KANBAN). The lean thinking mandates that every business activity adds value.

Lean Production System (based on TPS- Toyota Production System) is driven by the five lean principles:

Value – Understanding the value of the work we perform by defining it as something that our customers want to pay for.

Value Chain – Mapping the process steps that we perform throughout the supply chain by identifying the steps that add value and striving to eliminate those that add waste.

Pull – Eliminating the primary sources of waste – overproduction – by only producing what customers want, when they want it. This means starting production only when the customer “pulls.”

Flow – Removing other major sources of waste – bloated inventory and waiting – by ensuring that goods flow continuously through the supply chain and never stop.

Kaizen/Continuous Improvement – Striving for the total elimination of waste through a succession of small, action-oriented (kaizen) events within the production process.

To compliment the Lean in business improvement projects often is utilized the well known Six Sigma approach. Six Sigma is a data-driven set of standards that drives the exceptional quality in operations. It requires in-depth statistical metrics to analyze quality at all levels of the supply chain, eliminating defects.

In addition to Lean Systems, Catherine’s past experience includes implementations of some of the latest Business Management concepts like leading the development of Knowledge Management System as a tool for business collaboration in the early product development; and the evaluation and implementation of a PLM (Product Lifecycle Management System). With a broad range of professional certifications, which include a license as a professional Engineer with the PEO, Masters Degree in Mechanical Engineering and a Masters degree in Robotics and Automation, Catherine specialize in Corporate Assurance and Integrated Management Systems (ISO 9001-2000 Implementation, ISO 14001 Implementation, OHSAS 18001 Implementation). She is especially skilled at integrating all aspects of business Process Re-engineering and Change Management. Her past assignments include successful tenures at a number of large multinational enterprises and Ontario government to promptly deliver multi-billion dollars project-based solutions to customer needs, while building flexible infrastructures to maintain competitive advantage.

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HIGHLIGHTS OF QUALIFICATIONS:

• MSc degree in Mechanical Engineering, Major in Quality
• MSc in Robotics and Automation
• Over 10 years leading Quality Management and Process Re-engineering
• Solectron Key Contributor Award recipient for performance excellence (2006)
• 5S Corporate Service Site Award (2006)
• Health & Safety President’s Award recipient (2003)
• Memberships: ASQ, PEO (Professional Engineers Ontario)
• Strong Management skills with ability to mentor and motivate others
• Analytical and forward thinking, excellent problem solving skills, team player
• High Ethical and Professional standards
• Visionary and goal oriented change agent
• Certified Lean Sensei trained by Shingijutsu- Japan



*** Quality, Environmental and H&S Management; Business Systems Analysis & Improvement;

• Successfully implemented Quality Management System , Environmental Management System and Health & Safety Management System (TS 16949;ISO 14001; ISO 9001:2000; OHSAS 18001) achieving 100% compliance (QMS/ EMS )
• Successfully managed Quality and Continuous Improvement (CI/ BPI) by resolving highly complex multi-faceted problems to meet the business needs with a specific focus on creating tangible/measurable (CTQ) operational efficiencies through the application of business, financial, and process engineering knowledge. Realized $1 million dollar savings from lean initiatives in year 2006 P&L
• Managed Lean System Deployment (LSS) in conjunction with Operations Managers by Implementing Continuous Improvement (CI) methods and strategy
• Managed projects in Manufacturing and Service Industry for Fortune 500 companies in Automotive, High Tech. and Electronics, Engineering, Packaging, Printing, Design, Logistics Hubs, Supply Chain, Digital Media, Government, Communications, Wireless, Finance, Telecommunications, Transportation , Technical Infrastructure, Automation, Precision Plastics, PCBA, Assembly , Software development
• Developed Policy for Corporate Governance and Secured Regulatory Compliance
• Developed, implemented and assured compliance of new end-to-end best of breed quality assurance/control processes, policies, procedures, standards & methodologies and successfully delivered & supported new systems, technology & products through in house & external development integrators.
• Developed and managed audit programs (Audit Manager); TS 16949 and ISO 9001 Auditor;
• Trained 50 internal auditors. Conducted Internal Audits, Facilitated Certification Audits and Surveillance Audits, Completed QMS Gap Analysis reports and benchmarking ; Implemented LPA (Layered Process Audits) ; H&S incidents investigations WSIB ( Form 7)
• Developed Manuals, Proposals, SOP / Standard Operating Procedures Work Instructions, Control Plans, FMEA, PPAP , ECO / ECR ; MSA ; Gage R&R ; DVP&R ; BOM ; 8D ; 7 Steps; Supplier Quality Matrix ; SQ Scorecards
• Chaired Management Review Meetings, Led Change at all business operating levels , Chaired Change Board to coordinate software and hardware change / mechanical and electrical
• Corrective Action Process Owner for the business unit (CAP)
• Experienced in Document Management and Document Control, Revision Control, Security Policies (Department of Defence and Ontario Government) , Compliance Management
• Experienced with Change Management, Privacy Laws, Contracts and legal aspects
• Provided Project Support and Planning, Led the implementation of corporate initiatives
• Completed Statistical Data and Risk Analysis, Environmental Risk Assessment and Legal Review , Quantitive and Qualitive Analysis
• Developed efficient Electronic Document Management Systems using variety of platforms. (SmarTeam PLM, Domino/Lotus Notes) Reduced the impact of compliance documentation on profits by $8000 weekly, including e-learning strategies, knowledge management and document control; Engineering Change Management
• Delivered Health & Safety and Environmental Risk Assessments; Ergonomics evaluations ; Emergency Preparedness Manual and Disaster Recovery Plans ; Developed H&S Manual
• ANSI Z 1.4, ISO/TS16949, QS9000, OHSAS 18001, ISO 17799 ( IT Security Assessments),RoHS, IPC 610 , ESD , MSDS, SOX
• Managed projects to implement solutions to business problems with mitigating business risk and secured ROI of 365%, payback period of 9 months, investment of $468 000 and cycle time improvement of 25%. This involved opportunity identification, preparing business case proposals, defining business requirements and processes, developing testing, conversion and implementation strategies, developing detailed project plans, monitoring progress against planned objectives, and securing consensus and co-operations from users and senior management.
• Evaluated and delivered comparative business analysis for Product Lifecycle Management Systems (PLM), Negotiated with vendors ( IBM , UGS) ; CRM ; RFI / RFP
• Increased customer satisfaction by 80% through process re-engineering
• Realized $340 000 in savings by billing integration process improvement utilizing lean strategies
• In depth knowledge and experience in Advanced Product Quality Planning (APQP) , New Product Introduction (NPI), Program Management, Production Scheduling & Planning , HC (Headcount) Management , Lean principles of Flow , Pull and Push , TAT ( turnaround time ), Production line tact time , Total Quality Management, (TQM), Six Sigma Lean , TPS
• Developed and delivered training materials and programs for achieving savings objectives via Kaizen Blitz events, 5S, Visual Management and team building, JIT
• Mapped Business Processes and utilized lean strategies for improvement , business analysis or migration to electronic processes
• Utilized Value Steam Maps (VSM) for Value Added and Non-Value added analysis, Facilitated Kaizen Events and Six Sigma Projects (Continuous Improvement /CI)
• Worked to design and transfer large scale manual processes for automation by building business requirements and providing process expertise
• Selected process parameters, analysed risk (Failure Mode and Effect Analysis / FMEA), optimised process parameters, developed Control Plans to control and improve the Process Performance
• Developed Leadership program, training plans and delivered training to 500 employees (100% ISO, new employee orientation, H&S employee training, WHMIS, TDG, Kaizen introduction and Six Sigma Lean) ;
• Developed and Managed ISO and Engineering Intranet Workgroup created web content management for knowledge management delivery and metadata modeling according to International standards



***Engineering

• Experienced in distribution, Know-How, Technology transfer
• Over 6 years Engineering Design, Research and Development (R&D) experience
• Developed Engineering Documentation, blue prints, specifications
• Experienced in metalworking technology, production and R&D, Electromechanical Sensors, Prototype Series, Industrial Engineering, flexible automation & Robotic Industrial lines Japanese Plant Environment – Fanuc
• AutoCAD, SPC (Statistical Process Control); Minitab ; GD&T ; Control Plans ; FMEA


***Organizational and Management Skills

• Strong leadership skills, Interpersonal and motivational skills, able to think and act independently and proactively, driver of change process
• Effectively managed and supervised staff through project assignments by setting or providing input for performance expectations, monitoring performance, providing performance feedback
• Initiative, creative, composed, analytic/systematic thinker
• Relationship builder, results oriented, detail oriented, excellent time management skills
• Developed and prepared Executive Business summaries and presentations
• Managed Programs and several Projects simultaneously
• Handled appropriately sensitive and confidential material
• Coordinated and chaired meetings, both internal and off-site
• Over 3 years teaching experience at the University Level /Theory Of Automation Control

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“Catherine is a seasoned leader in Lean Six Sigma. She possesses extensive knowledge in all aspects of Lean & Six Sigma Deployment. Her work at Harris has proven to be solid and strong by leading a number of various Lean & Six Sigma training courses. Catherine would be a great asset for any company because of her knowledge, skills and experience to achieve solid results in your organization. Catherine's experience can lead to a success of any organization by improving processes to achieve optimum cost savings and quality improvements.” March 31, 2009

Banty Darji , Project Manager , Harris Broadcast Corporation
worked directly with Cathy Ethier, at Harris Corporation

“Catherine is a highly knowledgeable GRAND MASTER at Lean Six Sigma process, and is talented professional engineer. She specializes in several engineering disciplines, including electronics, mechanical and quality assurance / control.” January 6, 2009

Robert Legault , Senior Component Engineer , Harris Corporation
worked with Cathy Ethier, at Harris Corporation

“Catherine Ethier is a top Lean Six Sigma Master Black Belt who is proficient in training at all levels, curriculum development, project coaching, tools and methods, team facilitation, project identification/selection/and prioritization. She is strong in DFSS, TRIZ, and numerous other business process improvement methodologies. Catherine is experienced in working in numerous business industries and functions, from the shop floor to the executive staff. She is customer centric, strong in metrics, and linking strategy objectives to project execution results that deliver significant ROI value to both the businesses she has supported and the customers she has served. I fully endorse he abilities to work as a change leader in complex business processes, developing highly skilled resources, and in team effectiveness. Catherine is an asset to any business improvement effort and recommend her fully.” November 4, 2008

Steven Bonacorsi , Vice President , Six Sigma Live
was with another company when working with Cathy Ethier, at Harris Corporation

“We hired Cathy for our Corporate Quality department for her extensive experience and qualifications in the quality field. We crossed paths again in at the divisional level where she helped our plant attain ISO 9001 and later on TS16949 certification. She is very detail oriented and prepared us very well by outlining our deficiencies and providing us tracking tools to improve our processes and procedures. Cathy proved herself as a very knowledgeable heavyweight in her area of expertise.” April 6, 2009

Kevin Pang , Human Resources Associate , Progressive Moulded Products Ltd.
worked with Cathy Ethier, at Progressive Moulded Products Ltd.

“Cathy Ethier was my internal auditor for 1 1/2 years and assisted in achieving two TS16949/ISO 9001 certifications in that time. She is dedicated to her profession and understands her role as to how it impacts the manufacturing facilities. Cathy also provided assistance to the facility offering support on plant system changes and improvements. Jim Moher” November 11, 2008

Jim Moher , Plant Manager , PMP Ltd
managed Cathy Ethier, indirectly at Progressive Moulded Products Ltd.

“Cathy Ethier attention to details and dedication helped Omron to upgrade their documentation system and to improve their productivity. She always works hard to meet/exceed company objectives.” November 8, 2008

Farzad Azizi , Design team leader / R&D team leader , Omron Dualtec Automotive Inc.
worked with Cathy Ethier, at Progressive Moulded Products Ltd.

“CathEthier is the Leader who your company would love to hire because she can help your internal resources to achieve higher results in improving your business processes in achieving higher cost savings and quality improvements.” November 3, 2008

Dorina Grossu , Program Manager , Progressive Moulded Products
was with another company when working with Cathy Ethier, at Progressive Moulded Products Ltd.

“Catherine is a highly accomplished continuous improvement manager with the proven skills and abilities to motivate, coach and lead her teams through the most challenging operating environments inside a hyper competitive industry. I have worked with Catherine and have been impressed with her dedication and drive to succeed. Catherine is the type of leader that does whatever it takes to accomplish the task at hand and is not afraid to role up her sleeves and personally take on a difficult challenge. Catherine is a team player, with excellent partnering skills and has earned the right to be called "a leader". She holds herself and those around her accountable for surpassing business objectives, while taking on the responsibility to initiate and drive any changes that are needed in order to overcome potential roadblocks in the pursuit of these goals. Catherine will be an outstanding addition to the management team of any organization looking for a proven leader I had the pleasure of working with Catherine on several global projects. Catherine was a key component of the leadership team for the organization. Her innate ability to think strategically allowed her to quickly adapt to changing environments and develop solid plans that had a positive impact on business development and growth. She is a well respected leader not only with her direct reports but with peers and management alike. Her drive to succeed coupled with her strong interpersonal skills result” April 30, 2009

Nabeel Yousif, B.Sc., PMP, CISSP, CPITC , Network Systems/Support Supervisor , Omron
worked directly with Cathy Ethier, at Omron

“Cathy Ethier provided leadership and talent in the pursuit of systems integration, quality and lean manufacture solutions within Omron. She had been instrumental in helping institute company-wide cost saving procedures. She was also an exceptional and a very knowledgeable manager. During employment at Omron as a mechanical engineer/FEA specialist, she was always the best resource for my projects. She was well organized and diligent in managing projects. She was also very supportive, very thoughtful, easily reachable, and always on time.” April 7, 2009

Dennis liu , Engineer /FEA Specialist , OMRON
worked with Cathy Ethier, at Omron “

I have had the pleasure of working with Catherine over the course of several global projects. She has strong leadership acumen and is well respected by her direct reports and peer groups. Catherine is an exceptional leader who initiates change and partners extremely well. Catherine has the unique talent to lead Quality and Improvement Operational teams and has enjoyed a great deal of success and always obtained top rated results. Catherine has passion, perseverance and the ability to connect and coach. She has the drive, strategic vision and ability to influence others. She will be a tremendous asset to any organization.” April 6, 2009

Top qualities: Great Results , Personable , Expert

Steven Gregoire , Senior Director, PSO Subex Americas

Re: Kokatora DB “Thank you for your help driving the continuous improvement work for ODI and Omron. Hope to work together in the future.” 2005

Hideyuki Tokuda, Omron – Corporate, Japan