ROBERT T.

CREW
Raleigh, North Carolina 27615
www.linkedin.com/in/robertcrew
RobertTCrew@Gmail.com
(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.

Robert T. Crew

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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. Sicels 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 Oracles 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. Tycos 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 Engineerings New Product
Introduction (NPI) programs. Responsible for Engineering documentation releases (ECNs) using Oracles
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. EATONs 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
Presidents Merit Award from CEO in 1989 for dedication to the projects 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)

Robert T. Crew

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