Michael Kilcullen
Senior Associate at Rath & Strong- Claim this Profile
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Bio
Credentials
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Master Black Belt Lean Six Sigma (FAU University Executive Education Program)
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Experience
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Rath & Strong
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United States
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Business Consulting and Services
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1 - 100 Employee
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Senior Associate
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2018 - Present
Project Manager - Pfizer:• Throughput/flow re-design and project implementation for sterile injectables lines under maximum FDA scrutiny due to capacity constraints (creating shortages nationwide for global industry leader-client). Plan developed and mitigation efforts now underway to eliminate all constraints within 9 months. • Developing longer term metrics and tools for sustainable improvement. Implementing introduction of Total Preventative Maintenance (TPM) systems.• Remediation of Operational Deviation Events, Manufacturing Investigations, QARs and CAPAs.
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Sr. Project Manager/LSS Consultant
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2016 - 2017
Principle Program Manager & Lead Consultant for leading edge Lean Six Sigma Process Improvement firm: Last project saved $6MM in under 4 months for mid-level meat processing supplier through:• Waste reduction and process defect elimination;• Throughput improvement on highest volume capacity constrained lines;• Labor optimization both salaried and hourly. Principle Program Manager & Lead Consultant for leading edge Lean Six Sigma Process Improvement firm: Last project saved $6MM in under 4 months for mid-level meat processing supplier through:• Waste reduction and process defect elimination;• Throughput improvement on highest volume capacity constrained lines;• Labor optimization both salaried and hourly.
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Office Depot
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United States
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Retail Office Equipment
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700 & Above Employee
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Supply Chain Master Black Belt
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2013 - 2016
Supply Chain Master Black Belt (MBB) for Mid-West Region: Designed, Developed & Managed: Lean Six Sigma (LSS) roll-out for entire Supply Chain (Warehouses, Transportation & Logistics). 1) Drive from inception LSS throughout the Region including developing: • Strategy and leadership guidance on LSS implementation; • Green Belt & Black Belt level training materials for Lean & Six Sigma; • Infrastructure of reporting, metrics and accountability and a Train-the-Trainer system for ongoing sustainability. 2) Trained & Mentored 50+ managers in LSS & 9 Sr. Managers in LSS program management.3) Directed implementation of over 250 projects annually. Highest performing region (2x all other areas combined)4) Led directly high level, cross functional kaizen projects transformational to the business: • Module bench-marking and re-engineering project; • Capacity planning and modeling support team for Logistics/Supply Chain: • Corporate-wide projects such as furniture damage reduction to save $20MM.
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Mondelēz International
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United States
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Food and Beverage Manufacturing
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700 & Above Employee
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Sr. Program Manager & Netwrk Lead - Lean Six Sigma
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1998 - 2013
1) Procurement-Supply Chain – Lean-Six Sigma (LSS) Black Belt (Master Black Belt (MBB) In Training):Developed and directed 1st wave of supplier based Lean Six Sigma (LSS) initiatives for Meat Network ($1B spend): • Guided strategy development and metrics modeling. • Completed comprehensive Supply Chain-Value Stream Map process. • Directly managed implementation of Supplier Quality Engineering (SQE) initiative/Yield Optimization Projects. • Developed supplier accountability, specification optimization & defect elimination programs.2) Directed Lean-Six Sigma (LSS) Transformation Projects • Project Manager for complete Lean Transformation at Kraft’s largest North American Facilities reducing waste and raising processing throughputs. • Mentored black belts, green belts and production team leads on transformation efforts. • Created Production/ Flow system redesign for Kraft networks • Developed and initiated factory-wide Kanban pull & 5S system for all inbound and production supplies. • Led operations support teams for Logistics/Supply Chain projects that level loading distribution through warehouses, distribution centers, customer supply centers. 3) Certified Black Belt in Six Sigma Statistical Analysis & Business Improvement with excellent skills and experience in analysis of variance, statistical process control and design of experiments. 4) Operations Analysis: Recognized expert for Kraft in capacity analyses, process flows and computer modeling simulations. 5) Labor Optimization: Conducted Kraft-based, MOST (Pre-Determined Time Systems) blue card certification initiatives. Experienced in both Union and Non-union facilities.
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Nabisco
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Consumer Goods
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700 & Above Employee
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Manager, Operations Planning
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1998 - 2001
1) Developed and implemented capital, capacity and new product (commercialization) plans for all (9) of Nabisco's candy and gum plants.2) External Manufacturing: Negotiated, structured and managed outsourcing initiatives for confectionery products both domestically and internationally. Responsible for 8 facilities: supervised all facets of transition and coordinated cross functional teams. 1) Developed and implemented capital, capacity and new product (commercialization) plans for all (9) of Nabisco's candy and gum plants.2) External Manufacturing: Negotiated, structured and managed outsourcing initiatives for confectionery products both domestically and internationally. Responsible for 8 facilities: supervised all facets of transition and coordinated cross functional teams.
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Education
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1980 - 1982
Harvard Business School
MBA, Finance -
1974 - 1978
Hobart and William Smith Colleges
BA, Classical Greek & Economics
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