Julian Kalac
Lean Six Sigma Master Black Belt Continuous Improvement Manager @6-Sigma Engineering
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WORK HISTORY
Lean Six Sigma Master Black Belt Continuous Improvement Manager @6-Sigma Engineering
CA
Reporting to president accountable for delivering $2Mil/year savings, responsible for onsite deploying lean six sigma at customers facility, obtaining management support, idenitfying improvements, target setting, leading cross functional teams, achieving targeted savings, six sigma training• Achieved Lean Six Sigma Master Black Belt Certification-Successfully deployed over 40 Lean Six Sigma Master Black Belt cost saving projects in Manufacturing, SCM, Warehouse Distribution, Retail, IT and Finance resulting in over $30 Mil savings• Successfully Implemented Lean in Automotive manufacturing of Exhaust After Treatment System (EATS) for Volvo and Mack trucks, which increased productivity from 8 to 12 units/day, improved internal Quality Yield from 87% to 99.3%, resulting in total cost savings of $910K / year • Managed the implementation of 5S in a ft² plant, full implementation in < 3 months, resulting in over $400K labour savings in reduced material handling and machine downtime time • Deployed Design for Six Sigma in redesigning Switchable Water Pump Pulley (SWP), which reduced warranty failures from 8% to zero, reduced product cost by $1.32/pc resulting in $2.1 Mil/year savings • Deployed Lean Six Sigma in Pharmaceutical Vaccine Packaging, which increased productivity from 20 to 33 vials/min, reduced vaccine changeover time from 13 hrs to < 5 hrs, increased OEE from 19% to 34%, resulting in $1.4 Mil /year savings• Deployed Six Sigma methodology in Bio-Manufacturing, which reduced downstream batch processing time from 5 to 2 days/batch, increased First Pass Yield by 11%, Total savings=$ 820K/year•• Deployed Six Sigma methodology in Retail, improved Accounts Payable invoice payment accuracy from 64% to 99.2%, automated 3 way matching of Purchase Order, Receipt and Supplier Invoice, applied GL coding through the workflow process, Implemented Control Plan with Internal Audit process. Total savings =$630K/year in reduced Cost of Poor Quality
EDUCATION
CI INSTITUTE
Certificate, Master Black Belt Lean Six Sigma
BMGI
Six Sigma Black Belt, Six Sigma Black Belt
Ryerson University
Bachelor of Engineering (BEng), Mechanical Engineering
Ryerson University
Bachelor of Engineering (B.Eng.), Mechanical Engineering
SKILLS
ABOUT JULIAN KALAC
Results driven Mechanical Engineer and Certified Lean Six Sigma Master Black Belt with over 20 years of continuous improvement experience leading & implementing Lean Six Sigma cost saving process improvements in Manufacturing, SCM, Warehouse Distribution, Retail, IT and Business Processes. Experienced in using AI, Machine Learning with Lean Six Sigma to automate data analysis, predict defects before they happen, automate manual tasks, and achieve faster cost savings Demonstrated record of success with over $41Mil cost savings delivered through increased Productivity, reduced Operational costs, increasing efficiency, new business revenue • 20 years as certified LSS Black Belt, deployed over 55 Black Belt projects, with Avg savings=$510K/project• 15 Years as Lean Six Sigma Master Black Belt, deployed 16 enterprise projects resulting in over $14MIL savings and trained, mentored and certified over candidates as Lean Six SIgma Yellow Belt, Green Belt and Black Belt, each candidate completing a certification project and certification examProven track record in driving transformational change in diverse environments and achieving results quickly.
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