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SOFIA  Gilchrest

309 Canal Ln., Seaford, DE 19001                      302-249-9876                         sofia@comcast.net

Sr. Process Improvement & Quality Management

Process Reengineering / SPC/ QC / Product Development / Plant Management / Lean / CPI / Six Sigma Productivity Improvement / ISO / TQM / Sustainability / Testing & Standards / Operations / Offshoring

Working in product design/development, manufacturing, and quality management roles for DuPont and Invista, I increased productivity, quality, efficiency and customer satisfaction while tightly containing costs and maximizing profitability. By eliminating waste while boosting throughput, my contributions have consistently had a measurable positive impact on the bottom line. I can immediately contribute in a new environment by:

r  Marshaling diverse multidisciplinary resources to anticipate and resolve customer requirements

r  Optimizing manufacturing processes to maximize productivity and contain costs

r  Driving new products from R&D through commercialization to production

r  Ensuring best-in-class quality end-to-end from design to delivery

r  Developing innovative and cost-effective Green initiatives

Known for holding myself and those around me to exceedingly high standards, I ensure excellence at every turn. I hold a BS with Honors in Chemical Engineering from the U. Mass. Amherst. I have a Lean Six Sigma Black Belt certification from Villanova and a Green Belt from DuPont. I am also a certified ISO9001 Lead Auditor.

Selected Accomplishments

Operations/Compliance/Quality Leader of Small Business Improved reputation with state environmental organization through strict adherence to environmental & OSHA compliance including instituting a compliance calendar.  Drove quality improvement via audits, checklists, and improved measurement recording.   Began profitable turns of sequenced runs to minimize downtime and balanced working capital versus order quantity to turn the business into a profit center.

Played key role revitalizing tired line with 104 new products. Limited color palette was hurting Invista fiber sales. Tasked to increase scope of product offerings. Developed and executed plan to expedite commercialization and testing. Brought new high-margin fibers to market, doubling number of SKUs to create $5M revenue stream.

Built Green product portfolio. Invista wanted to enhance its reputation for sustainable manufacturing. Collaborated with R&D to identify products most suitable for reformulation. Developed and released 51 new SKU’s. Increased post-industrial content from 7 to 25% for product line valued at $10M, strengthening Green presence.

Turned around troubled commercialization program. Planned DuPont launch of 30 new products at major trade show was threatened by bottlenecks/silos in R&D and production. Took over program, fast-tracking R&D and pilot runs. Turned project around in six weeks, meeting tight deadlines with delivery of projected best-selling new line.

Implemented innovative process, driving $3.5M productivity gain. Invista marketing team was pushing for expanded color portfolio that required prohibitively expensive production. Proved business case for alternative process. Putting new process in place, enabled manufacturing of new colors and 5% higher yields on existing production totaling 65 million lbs of output. Increased productivity, generating 2% profit gain on $70M cost of goods.

Solved critical offshore quality issue. Japanese DuPont client required use of its own local supplier whose pigment quality was subpar, causing inconsistent coloration. Stepped in on both client and vendor sides, with fixes for raw material and process defects. Ensured consistent quality for client.

Resolved StainMaster® production defect and rebuilt customer trust. Introduction of DuPont flagship fiber was threatened by incidence of carpet streaks at several key customers. After exhaustive investigation, traced defect to a single early production run and recalled batch. Regained confidence among key accounts and within DuPont.

Eliminated air permit reporting deviations. Invista was suffering from excessive deviations from state air quality permits. Conducting 360° review, determining nearly all deviations were paper-only and not actual emissions. Corrected reporting process/measuring system defects, cutting deviations from 170 annually to zero first year and maintained at that level year-over-year.

Reengineered process to retain key client. New DuPont coating formulation was well-received by most users, but one major account had serious compatibility issues. Worked directly with client engineering team, revamping their dye process. Maintained broad advantages and lower cost of new formulation while creating cost-effective work-around solution for single client’s special requirements.

Maximized ROI on inventory liquidation in plant closure. Invista BCF plant to be shuttered was expected to return pennies-on-the-dollar for left-over raw materials. Optimized liquidation process to get top prices. Obtained unheard-of 75% of cost while minimizing volume of materials needing to be destroyed or recycled.

Career History

Operations Manager/New Product Development for ActivAir, Inc. (May 2011 to current) providing Operations Direction, Compliance Responsibility, Quality Assurance, Project and New Process Development to grow an acquired business from bankruptcy to successful profitability by managing operating budget, minimizing waste, improving quality, & introducing new products based on our core technology.

Owner, (April 2009 to May 2011) CheChem Color Solutions, providing a vast array of color control, formulation and measurement knowledge aimed at improving the efficiency of our clients’ color business.

Optimizer/Process Improvement Engineer/Quality Leader (May 2004 to March 2009), Invista, a division of Koch Industries spun off from DuPont. Recruited in 2004 to manage production of 65 million lbs of fibers annually. Played key role in developing new products and processes, collaborating closely with R&D, marketing and manufacturing teams, as well as customers. Downsized in major force reduction when business unit was relocated overseas in 2009.

E.I. duPont de Nemours & Company  (June 1980 to April 2004)

Measurement and Quality Engineer, 1991-2004. Directed color measurement and other quality management processes across multiple manufacturing sites.  Managed in-house lab charged with QA for 65 million lbs/year.

Quality Leader/Process Improvement Engineer, 1985-1991. Managed quality assurance on production of 50+ million lbs annually. Implemented and trained staff on TQM/Crosby quality management protocols.

New Product Development Engineer, 1980-1985. Developed 10+ new products for staple flock business. Reduced costs and improved existing processes, enabling dramatically improved production yields.

Personal

A dedicated dog-owner, I also enjoy bowling, gardening, jewelry-making and DIY home improvements. I am also active in my church, local civic and charitable groups.

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