Robert Crew is results-driven and dedicated with over 25 years of progressive Manufacturing Operations Supply Chain expe...
ROBERT T. CREW Raleigh, North Carolina 27615 www.linkedin.com/in/robertcrew
[email protected] (919) 332-2323 (Cell)
Director of Supply Chain and Manufacturing Operations Supply Chain Management
New Product Introductions
Program Management
SUMMARY: Results-driven and dedicated with over 25 years of progressive Manufacturing Operations Supply Chain experience planning and leading New Product Introduction teams at both Start-Up companies and larger corporations. Strong track record of evaluating, re-engineering, and implementing process improvements to reduce costs while improving quality yields. Broad experience in both Program Management and Supply Chain Management (Outsourcing) in the Consumer Electronics, Telecommunications, and Medical Device industries to support commercial launches. AREAS OF EXPERTISE: Supply Chain Management Manufacturing Engineering MRP/ERP System Implementation Just-in-Time Production (Lean Mfg)
New Product Commercialization Purchasing and Negotiations Contract Manufacturing (EMS) Materials Management
Program Management Cost Reductions Product Costing Manufacturing Strategy
PROFESSIONAL EXPERIENCE:
TearScience, Inc.
- Medical Devices (FDA - Ophthalmology)
September-2011 to Present Morrisville, North Carolina TearScience is a medical device company that designs and manufactures equipment to identify, diagnose, and treat Meibomian Gland Dysfunction (MGD), the leading cause of dry eye, with a solution that restores gland function. Products are FDA cleared for distribution and marketed worldwide. TearScience's 2016 revenue run rate was $30 Million and has approximately 120 employees.
Director Supply Chain and Manufacturing Operations
Jan-2012 to Present Managing commercialization scale-up of Supply Chain and Production activities focused on: Supply Chain Management ($18 Million annual spend with 4 month cumulative product lead times) Executing Master Production Schedule (Supporting 20+% growth 3 consecutive years) Dual Sourcing for critical products (Recovery capacity and price competition) Product Availability (92% On-time Customer shipments) Cost Reductions (Yield/Process/Design improvements) Lead Time Reductions (Minimize inventory) Responsible for the following functions: Demand/Production Planning, Supply Chain/Procurement, Receiving, Stockroom, Manufacturing, Logistics/Shipping, Inventory Management, Manufacturing Engineerig, Product Costing, MRP System Administrator, and Prototype Machine Shop. Facilitated Sales and Operations Planning (S&OP) meetings to manage Demand Planning activities. Utilized historical data for trend analysis and measured Forecast accuracy refining the Production Plan to support revenue goals within financial constraints.
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Management Consultant > Supply Chain and Manufacturing
Sep-2011 to Dec-2011 Engaged as a Management Consultant directly by the CEO to evaluate TearScience's manufacturing strategy and recommend improvements including: Operations overview and infrastructure (Manufacturing Scale-Up for commercialization) Cumulative lead times per product (Inventory exposure and pipeline materials strategy) Supply Chain assessment (Evaluated process flow and Supplier risks) Capacity analysis (Support revenue plan ramp-up) Product costing and cost reduction opportunities (Improve gross margins) Forecasting performance (Develop Demand Planning/S&OP process) Key Accomplishments: Set-up entire MRP System integrating Sales Orders, Purchasing, Receiving, Production, and Shipping. Supported $11 Million revenue for first year commercialization and almost doubled in second year! Achieved 30% cost and 33% lead time reductions and increased capacity 57% on one product. Implemented $430k annual cost savings through hard-tooling low volume plastics (RIM technology). Assessed high volume plastic injection over-molding companies and selected Supplier. Obtained 12+ Annual Inventory Turns in a cGMP (FDA 21 CFR 820) and ISO 13485 Quality System.
SICEL TECHNOLOGIES, INC.
- Medical Devices (FDA - Oncology)
August-2002 to August-2011 Morrisville, North Carolina Sicel Technologies was a Start-Up medical device company that designed and manufactured radiation sensors for oncology cancer therapy. Sicel’s products were considered first-in-class implantable, telemetric sensors when initially filed with the U. S. FDA. Products were 510(k) Cleared for distribution and marketed worldwide. Annual revenues were targeted at $70M after a four year ramp. I was the first employee hired to develop the Manufacturing Operations function and managed a $3M+ budget. Sicel had 53 employees.
Director of Manufacturing and Distribution
Aug-2002 to Aug-2011 Responsible for developing the overall Manufacturing Operations Strategy (Outsourcing) focusing on Core Competencies. Directly managed seven positions within a cGMP compliant and ISO 13485 certified facility. Responsible for the entire Manufacturing Operation (Internal and External) including: Manufacturing Strategy: Focused on internal core competencies (Radiation Calibration). Outsourced mainstream processes (Wafer Fabrication, Electronics, Packaging, and Sterilization). Partnerships with Key Suppliers (Entrepreneurial Supplier Development) New Product Introductions (NPI): Worked with Engineering, Quality, and Regulatory to launch products for commercial Distribution. Launched new version of product increasing Manufacturing Yield from 77% to over 97%. Released Engineering Designs using Oracle’s Agile PLM (Product Lifecycle Management). MRP / ERP System Implementation: Created infrastructure for Start-Up company by implementing a MRP System and SOPs to procure inventory, receive, store, issue to work orders, convert to Finished Goods, accept Customer Orders, and invoice/ship products for revenue. Created Item Masters and Bill of Material (BOM) structures implementing pc/MRP System. Set-up MRP System to support Lot Traceability for cGMP Medical Devices (FDA – 21 CFR Part 820). Demand Planning (S&OP): Reviewed historical product shipments for trend analysis to predict monthly production demand. Adjusted Buffer Stock of Finished Goods Inventory to support Customer Service Levels. Drove MRP Demand using Master Production Schedule (MPS) based on Forecast and Yields.
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Supply Chain Management: Managed procurement of $2.4 Million of component inventory (Annual Spend) for production. Responsible for Supplier selection, sourcing, and negotiating Full-Turn-Key Contracts. Developed predictive model to manage 9-month cumulative lead-time detailing yield/scheduling. Production and Inventory Control: Managed Contract Manufacturers (CMs / EMS) and re-scheduling activities. Reduced Physical Inventory by 28% in one year by implementing Lean Manufacturing principles. Managed Buyer/Planner positions minimizing Excess and Obsolete Inventory. Manufacturing and Distribution: Managed receiving, stockroom, kitting, work orders, production, and test functions. Managed Customer Service (Sales Order Entry) function. Shipped directly to USA Customers and utilized Distributors for International orders. Product Costing: Developed Standard Costs for products based on EOQ and Lot Sizes to minimize PPV. Created overhead cost model (Fully Burdened) detailing factory labor rate per product line. Developed budgeting tool for work order variances based on historical step-level process yields. Manufacturing Engineering: Defined process flow and developed facility layout including class 10,000 clean room. Developed process procedures (Both SOPs and product specific). Technical support (DFM) for micro-electronic hybrid assemblies on FR4, flex, and ceramic substrates including SMT, flip-chip, and wire-bonded technologies (IPC A-610 & MIL-STD-883). Quality Assurance: Generated Device History Records (DHR) per Lot within ISO 13485 Quality System. Tracked historical yields per process step detailing scrap costs for each production lot. Managed lot traceability for components consumed and products shipped to Customers. Key Accomplishments: Developed 5-Year Strategic Capacity Plan to support $70M potential revenue (Headcount and Capital). Launched two product families (OneDose and DVS) receiving 510(k) Clearance from FDA. 95%+ on-time Customer shipments for both domestic and international orders. 30% product cost reduction changing from Flip-Chip to SMT packaged part Reduced cumulative lead time by 30 days improving Logistics.
TE Connectivity (ADC Telecom)
- Telecommunications
August-1998 to August-2002 Raleigh, North Carolina TE Connectivity provides broadband data access and infrastructure equipment to RBOCs (AT&T, Verizon, and Time Warner Cable) for telephone and internet access. Tyco’s revenue for 2014 was $12 Billion with over 75,000 employees.
Senior Advanced Manufacturing Engineer
Aug-1998 to Aug-2002 Represented Manufacturing Operations in a satellite R&D facility supporting Engineering’s New Product Introduction (NPI) programs. Responsible for Engineering documentation releases (ECNs) using Oracle’s Agile PLM software. Procured prototype inventory using both Oracle and SAP MRP Systems. Performed Design-For-Manufacturability (DFM) analysis of SMT PCBAs and was responsible for product costing. Completed on-site Supplier Quality Audits and was responsible for Supplier selections. Supported the Manufacturing Model (Contract Manufacturers in both Mexico and USA) through extensive travel to manage projects, NPI, and resolve problems on sustaining production to protect revenue.
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Key Accomplishments: Achieved a 70% component cost reduction by implementing a Die Casting source (was bent steel). Developed Rapid Prototype supplier for printed circuit board assemblies (PCBAs) that quickly turned designs into products in just one (1) day which helped reduce the overall Design Cycle. Doubled capacity at Contract Manufacturer (EMS) by analyzing bottlenecks to improve their thru-put.
EATON (Powerware Division)
- Electronic Power Supplies
August-1987 to August-1998 Raleigh, North Carolina EATON Electrical designs, manufactures, markets, and services uninterruptible power systems, related equipment, and power management and facilities monitoring software to protect mission critical applications at hospitals, data centers, industrial process equipment, and personal computers. EATON’s revenue for 2014 was $22.6 Billion USD with over 99,000 employees.
Manufacturing Technology Manager
June-1997 to Aug-1998 Managed team of Engineers responsible for launching New Products into the marketplace representing Manufacturing Operations. Coached nine exempt employees on Program Management techniques. Allocated resources to maintain project schedule deliverables. Developed NPI Capital Plans and managed a $700k department budget. Key Accomplishments: Outsourced Production from Mexico facility to Contract Manufacturer in Philippines to increase capacity. $3 Million annual savings implementing China Supply Chain (Plastics, Metal, Transformers, and PCBAs)
Program Manager / Manufacturing Technologist
Oct-1994 to June-1997 Representing Manufacturing Operations, launched new products into the marketplace working with Design Engineering, Marketing, and Quality teams. Program Manager tasked with Project Planning (Time-ToMarket) focused on First Customer Shipment responsibilities including: Manufacturing Strategy Achieve Product Cost/Yield Goals Engineering Releases (ECNs)
Justify Capital Equipment Define Process Flow/Layout Prototype Inventory
Own Transition to Full Production E&O Material Disposition Assure Manufacturability (DFMA)
Key Accomplishments: Launched product designed in Helsinki, Finland into production facility in Wilmington, North Carolina Launched products designed in Raleigh, NC into either Wilmington, NC or Tijuana, Mexico facilities
Senior Industrial / Manufacturing Engineer
Aug-1987 to Oct-1994 Promoted to various Engineering positions over seven years with experience/accomplishments including: New product introductions, Engineering Change implementations, new facility start-ups, product costing, production supervision, and process/quality improvements. Key Accomplishments: Obtained initial Project Management experience by implementing a "Lean Manufacturing" JIT-Focused Factory manufacturing cell which successfully reduced lead times and inventory levels, increased capacity, improved quality, and decreased layout requirements saving over $3 Million dollars in one year. Received President’s Merit Award from CEO in 1989 for dedication to the project’s success.
EDUCATION:
NORTH CAROLINA STATE UNIVERSITY (NCSU)
Raleigh, North Carolina
Bachelor of Science, Industrial Engineering (BSIE) CERTIFICATIONS:
Certified in Production and Inventory Management
July 1995 (CPIM by APICS – the premier professional association for supply chain management)
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