WESLEY W.

HACKNEY

910-639-5235(Wk-cell) 531
Edinboro Dr. Southern Pines, NC 28387
910-944-7784(Hm)
Email:w
hec5006@westpost.net
OBJECTIVE
A critical leadership role as a change agent with an organization utilizing my
extensive hands-on experience in manufacturing to grow the bottom line and compe
te in the current economy through the use of Lean Sigma principles.
PROFESSIONAL EXPERIENCE
ARGO Inc, Chicago, IL
November 2010 a" Present Senior Lean Co
nsultant a" Working in US, Canada, and Europe with a variety of companies rangin
g from, railroad, plastics, electronics, medical devices, and corrugated cardboa
rd analyzing and implementing lean and six sigma cultures to reduce costs and im
prove productivity. Served as a mentor to other consultants in learning how to
implement lean.
Accomplishments
a Achieved 25% reduction in turnaround time for railcars (30 to 24 hours) for on
e railroad company in a period of 8 months improving the on-time rate from 30% t
o 90% while working with a union organization.
a Worked with electronics company to reduce inventory from $5M to $3.5M (30% red
uction) implemented over a period of 3 months.
a Led kaizen events with plastics extruding and converting company to improve ma
chine uptime by 10% over a period of 2 months resulting in an additional project
ed annual sales of $3.6M
a Successfully worked with a team of other consultants to develop a master plan
to implement a six sigma project schedule for a European corrugated cardboard co
mpany encompassing 20 facilities.
ARVINMERITOR, Maxton, NC
August 2007 a" October 2009 Plant Lean Expert a" Served
as lead person to implement Lean manufacturing principles from the ground up as
a part of a company wide initiative. The Maxton facility manufactures Military
and Commercial Axles, Transfer Cases and Drive Shafts with records sales in 200
9 of $450M. Primary responsibility was to lead the plant in development and imp
lementation of an overall long term lean strategy in keeping with the TPS princi
ples.
Reason For Leaving: Part of companywide reduction in force of 10% during peak of
US recession.
Accomplishments
a Achieved an overall plantwide productivity improvement of 25% over 2 years fro
m a baseline in August 2007 of 36.1% to 62.2% in September 2009.
a Reduced inventory from $22K to $11K and increased inventory turns from 12 to 1
9.5 by implementing a plant wide Kanban system for all small parts kitting opera
tions and eliminated 50% of bulk materials stored in the central warehouse by co
nverting to line side staging at each production line.
a Developed a master plan to implement 5S process including self directed 5S tea
m in each production area.
a Led plant in development of preassembly kitting process saving $240K in annual
labor savings.
a Led a lean transformation of Drive Shaft area resulting in improving productiv
ity 19 6% to 39.1% in 15 months.
SIMONDS INTERNATIONAL, Florence, SC Augu
st 2004 a" August 2007 Lean Coordinator a" Peer level with Plant Manager with ac
countability to VP of Manufacturing. Company wide effort to implement Lean Manu
facturing using TPS principles for a facility fabricating steel into knives and
saws for wood and industrial cutting applications. Developed short and long ter
m implementation plan with upper management then trained, mentored, and led Kaiz
en activities with all plant personnel. Served in same capacity with three othe
r plants.
Reason For Leaving: Florence plant closed which would required me to relocate to
New England facility.
Accomplishments
a Successfully converted 7 product families from batch to cellular manufacturing
reducing thru put time 60-80%, WIP inventory 50% and created over 20K sq. ft. o
f floor space.
a Established Kanban inventory pull systems for 4 product families and consumabl
e materials reducing finished goods inventory $1M and reduced finished goods inv
entory storage 50% in shipping warehouse.
a Worked with Maintenance Manager to start plant TPM program and introduced to s
hop floor.
a Introduced visual metric boards in all facilities to track daily/weekly perfor
mance & established daily walkthrus.
DANAHER CONTROLS, Elizabethtown, NC
July 1999 a" August 2004
Lean Sigma/Business Unit Manager - Hired as QA/DBS (Danaher Business Systems) Ma
nager reporting to VP of
Operations for plant manufacturing mechanical and electronic counters/controller
s, temperature controllers and circle chart recorders ($60 M annual sales). Pla
nt operation was based on Toyota Production System (TPS) manufacturing methods.
Initial objective was introduction of Six Sigma to the companyas overall lean m
anagement philosophy and skill sets known as DBS. Coordinator for all monthly K
aizen activities and continuous improvement projects. Added responsibility in
6/03 as Business Unit Production Manager for two production groups in the plant
with annual sales of $11M.
Reason For Leaving: Pursue career opportunity to assist company in implementing
Lean/Sigma from ground up.

Accomplishments:
a Achieved 50% reduction in plant warranty returns 2000 to 2004.
a Kaizen project activities have yielded over 15% to 18% improvement in producti
vity cost annually.
a Coordinated implementation of inventory reduction Kaizenas which reduced inven
tory from $5.4M to $2.8M .
a Corporate wide instructor\mentor for Lean\Sigma and conducted training & Kaize
n events at other plants.
a Part of two teams to transfer new product groups into plant. Partlow-West in
2000 and Thomson Industries in 2003. Each move involved converting the operation
s from batch to cellular manufacturing.
a Led 3 teams in relocating assembly operations to overseas locations in Brazil,
China and Czech Republic.
GENERAL ELECTRIC, Dothan, AL
June 1996 a" July 1999
Lead Blackbelt/Master Blackbelt a" Began as Lead Blackbelt for DC Motor Plant fo
cusing on use of Six Sigma and Lean skills to reduce manufacturing costs in all
areas of the facility ranging from production scrap/rework, process cycle time,
to inventory reduction. Completed GEas Master Blackbelt training and served a
s Master Blackbelt in 98/99. Reason For Leaving: Career path offered by GE
would require moving my family every 18 months.
Accomplishments:
a Personally responsible for projects resulting in over $500K annual savings in
1997 & 1998
a Established plant wide system to track production scrap resulting in projects
saving $350K in internal scrap.
a Trained and mentored salaried and hourly personnel in use of Six Sigma and Lea
n tools.
a Assisted in hiring and training 2 Blackbelts for Dothan.
a Worked with plant to exceed policy deployment savings goals of $1.4 M (1997),
$1.7 M (1998), $1.5M (1999)
ALLIED SIGNAL, Greenville, AL
January 1995 a" June 1996
Blackbelt - Responsible for coordination of process improvement, defect reductio
n, and lean manufacturing projects for Airbag and Seatbelt Assembly operations i
n Greenville and Knoxville in addition to Juarez and Aqua Puerta, Mexico.
Reason For Leaving: Greenville plant closing and relocating to Juarez, Mexico an
d I would be relocated to El Paso.
Accomplishments:
a Obtained Six Sigma Blackbelt Certification including Certificate Of Merit Awar
d For aMOST TENACIOUSa.
a Led projects contributing to reducing 1995 Plant COPQ $1.9 M, a 26% improvemen
t over 1994.
a Achieved a minimum of 75% reduction/improvement on all individual projects com
pleted.
a Conducted Greenbelt training for salaried and key hourly associates.
AKZO NOBEL FIBERS INC., Scottsboro, AL
1992 - 1995
QA Manager - Responsible for implementation and maintenance of process control
systems for a polyester and nylon industrial fibers facility. Managed staff res
ponsible for process control testing, customer service and vendor quality. Trai
ned in Germany\ Holland on ISO-9000 standards in manufacturing and led successfu
l completion of plant ISO-9000 certification. Technical liaison for alternative
polyester chip supplier in Monterrey, Mexico resulting in $1.5M savings per yea
r. Worked with engineering on process variation reduction projects resulting in
eliminating QA testing by 50%.
Reason For Leaving: Pursue career advancement and attain Blackbelt and Lean Manu
facturing Certifications
FUJI FILM INC., Greenwood, SC
1988 -1992
Quality Assurance Engineer - Trained 4 months in Japan learning production oper
ations, quality system implementation, and team problem solving. Served as spe
cial troubleshooter for suppliers not meeting standards
Reason For Leaving: Replacement of salaried American workforce.
ENGELHARD CORPORATION, Seneca, SC
1986 - 1988
Process Improvement Engineer - Responsible for coordinating relocation of QC fun
ctions from unionized facility in Newark, NJ to new chemical catalyst plant in S
C. Developed and introduced process improvement program to production
Reason For Leaving: Position eliminated due to corporate-wide restructuring.

BASF CORPORATION, Freeport, TX

1984 - 1986
Lab Manager/Production Chemist - Managed process control labs for six Acrylic Mo
nomer Plants.
Reason For Leaving: Pursue career advancement.
EDUCATION
UNIVERSITY OF TEXAS AT DALLAS, Richardson, TX
December 1983
MS Degree; Environmental Sciences
Maintained 3.7/4.0 GPA while working full time as a chemist at Lone Star Gas Co.
, Dallas, TX
NORTH TEXAS STATE UNIVERSITY, Denton, TX
December 1978
BS Degree; Chemistry (Minor:Math)
REFERENCES AVALIABLE UPON REQUEST