Operations / Manufacturing / Supply Chain / Procurement / Logistics Executive

San Jose, California, United States

Recruited by this Medical Device start-up company to turn around a failing Manufacturing and Operations department.

Responsible for managing all aspects of Operations including;
-  S&OP process and Sales Forecast rationalization
-  Production and Material Planning
-  Procurement
-  Manufacturing (outsourced in Asia)
-  Logistics and Global Trade Compliance
-  Distribution and E-Commerce Fulfillment (outsourced 3PL)
-  Strategic Partnership Development and Management.

-  Within 1st 30 days, successfully re-launched and ramped manufacturing after production had been at a standstill for 9 weeks. Enabled Nima to meet all critical Q4 quality, production and delivery objectives.
-  Implemented a formal S&OP process within 1st 30 days ensuring alignment between Sales demand and Operations supply.
-  Negotiated strategic supply agreements with critical suppliers.
-  Developed Cost Down Roadmap resulting in 46% Bill of Material Cost reduction.
-  Reduced manufacturing lead-time from 4 months to 3 weeks.
-  Developed a new Logistics strategy resulting in a 93% inbound Logistics Cost Reduction.
-  Sourced new Asian CM enabling company to avoid 25% tariff from current China based CM.

Nima Labs (acquired by Medline Industries)

Head Of Operations

Provide Operations, Manufacturing, Supply Chain, Procurement, Logistics, S&OP and Sales Channels of Distribution consulting and support services to U.S. domestic and international companies.

Start-up to Fortune 100 client base.

Sample client list includes: Acer, Brocade Communications, Calmar Laser, Robert Bosch, Neato Robotics, Tunebug, TVU Networks, Blackphone and other U.S. ,Europe and Asia based companies.

Sample engagements include:

- Developed new corporate S&OP process for a $2B data networking and storage company.
- Led a step function production ramp with Chinese factories for a U.S. consumer robotics start up.
- Completed an outsourced Big Box Retail order fulfillment logistics implementation with 3PL in less than 6 days for a telecommunications start-up.
- Architected and implemented Materials Sourcing, Manufacturing & Distribution strategy for Silicon Valley start-up in the wireless broadcasting industry.
- Implemented JIT manufacturing capability infrastructure reducing inventory cost exposure by 82%.
- Sourced suppliers, negotiated strategic partnership agreements; achieved a 42% BOM cost reduction.
- Restructured Materials Sourcing, Procurement, Warehouse and Materials Management infrastructure for a medical systems company.
- Completed all U.S. and European regulatory compliance requirements for a new 3G /4G data transmission product.
- Led materials sourcing and procurement efforts for critical components for a Fiber Laser manufacturer.
- Developed U.S. Marketing and Sales Channels of Distribution strategies for several European and Chinese manufacturers.

Impact Supply Chain Group

VP Operations

Recruited by this PE backed company to modernize the supply chain infrastructure and improve EBITA performance. Lead several Strategic Procurement, Supply Chain and Process initiatives across 12 manufacturing plants and 2 distribution centers.

- Developed and executed new Commodity Group Strategies resulting in over $2.6M cost savings in both direct and indirect spend categories within 5 months including;
-       Metals - (coil, extrusion, plate, sheet, rod, machining, finishing) - $500K cost savings
- Logistics - $1.2M cost savings.
- Automated PO generation and receipts process, reduced manual data entry by 99%.
- Restructured international logistics eliminating lost and delayed inbound shipments.
- Aligned Sales and Supply Chain via S&OP process - improved On Time Delivery to 99%.

Boyd Corp (acquired by Goldman Sachs)

Director, Corporate Supply Chain

Managed all Manufacturing, Quality, Planning, Material Sourcing, Purchasing, and Logistics.

- Negotiated pricing, manufacturing requirements and delivery with China based contract manufacturer.
- Sourced and secured suppliers for the Accessories product lines.
- Defined and executed the Quality Management Plan for Smartphone and Accessories product lines.
- Managed outsourced 3PL Logistics providers for global B2C and B2B fulfillment operations.
- Sourced and implemented a 3PL global distribution center partner shipping our products to over 70 countries on 6 continents.
- Implemented and managed reverse logistics processes for product returns.

Blackphone (acquired by Silent Circle)

Head Of Supply Chain and Quality

Managed all sub-contract manufacturing partners in China, component suppliers, global logistics and service provider activities and relationships for this start-up company.

- Secured outsourced manufacturing capacity to support production ramp from 20 to 10,000
units/week.
- Negotiated several strategic partnership agreements including capital investments by
key suppliers and service providers.
- Sourced and secured all materials from suppliers to support initial $20 million of finished
goods production without issuing a single Letter of Credit.
- Drove BOM cost reductions of 38%.
- Architected and implemented fulfillment operations supporting B2C, D2C, Big Box retail
and distribution partner demand.
- At product launch implemented a China Direct to U.S. Consumer Order Fulfillment model.
Customers received orders within 2 days of placing orders.
- Post product launch, restructured logistics with outsourced U.S. and China Distribution
Centers in less than 30 days to support B2C and B2B (Big Box retail partners).
- Reduced global freight costs by 70%.

Livescribe Inc.  (aquired by Anoto Group)

Sr. Director Purchasing, Planning & Logistics

Responsible for driving business process optimization initiatives for Polycom operations worldwide.

- Led and implemented numerous systems enhancement initiatives for Purchasing, Planning, Logistics, Order Management, Sales and Cost Accounting.
- Eliminated IT caused Late Shipments from 7.5% to 0% within 2 months of start date.
- Led international Trade Compliance project instituting an automated FIFO inventory system with outsourced manufacturer partner and ensured customs compliance for all shipments.
- Implemented Polycom’s first global S&OP process resulting in reduced freight cost expenditure by 46%, improved on time shipment performance, increased inventory turns and enhanced coordination of marketing and sales programs.
- Initiated Polycom’s first SKU rationalization process to drive focus on core products and profitability, remove unnecessary complexity.
- Completed a global Order Management Optimization and Automation project, dramatically increasing OM efficiencies while simultaneously improving customer satisfaction.

Polycom

Director, Worldwide Operations

Leveraging my global sourcing and supply chain expertise, founded Ventana in Q4 2001 to service the U.S. building materials and home furnishings market. All products sourced and manufactured in China, Thailand and Indonesia.  Sales and Distribution in the United States.

- Established Asia Purchasing Office and negotiated exclusive distribution agreements with suppliers.
- Launched 10 products in 2002 and expanded product offering to 15 products in 2003.
- Developed and executed multi-tiered marketing and sales strategies for each product line.
- Expanded customer base from regional to national within first year of operation.
- Achieved profitability within first 3 months of operation.
- Sold business in 2004

Ventana International

President

Managed all aspects of Supply Chain Operations for this Personal Video Recorder start-up company including; Procurement, Manufacturing, Distribution, Order Processing, Forecasting, Master Scheduling, Planning, Commodity Management, MRO Purchasing and Logistics.

- Developed Replay’s outsourced manufacturing & logistics infrastructure to support production ramp from 1000 units per month to 1000 units per day.
- Implemented a Commodity Management approach to stabilize Replay’s supply base, ensure materials availability and reduce costs.
- Negotiated “Best in World” pricing for key commodities.  Reduced BOM cost by 42%..
- Sourced and implemented new outsourced Distribution & Fulfillment Center, reducing costs by 75%.
- Established and led S&OP Process with Sales, Marketing & Finance.

ReplayTV  (acquired by SonicBlue)

Director, Supply Chain

CPD, a start-up division within SGI, developed a new Wintel based PC and executing an industry leading e-commerce and outsourced operational business model.

- Architected the global supply chain infrastructure for CPD to support a ramp from zero to $1B global operation in one year.
- Selected business partners in U.S., Europe and Asia and implemented Outsourced Manufacturing, Configure to Order, Build to Order, Zero Inventory business model.
- Implemented kanban and demand pull systems in manufacturing and distribution centers to ensure CPD’s Zero Inventory requirements were met.
- Initiated Consensus Forecasting process with Ops, Marketing, Sales and Finance teams.
- Redesigned distribution/ logistics model for CPD reducing logistics costs by $63 million over 3 years.
- Lectured Stanford Business class on CPD operations business model resulting in published paper.

Silicon Graphics

Sr. Manager, Supply Chain and IT

Implemented Oracle ERP software at a variety of customer sites in the U.S. and Asia Pacific region.

- Clients included Hospitals, Semiconductor Manufacturers, Capital Equipment Manufacturers, Electronics and Contract Manufacturers.
- Customers ranged from start-up operation to mid-size company and multi-national companies.
- Developed an accelerated Applications Implementation Methodology (Fast Forward), based on Standard Industry Business Processes and Industry Best Practices. Fast Forward reduced Oracle ERP systems implementation time by over 50%.
- Team Leader for Oracle’s Semiconductor Initiative, which designed new award winning software solutions for the unique requirements of the Semiconductor industry.

Manfred Flemme