Stephen Popichak
Oak Island,NC
Summary
High-performing, people-oriented leader with extensive experience in supply chain and manufacturing operations. Over 15 years of Lean/Six Sigma expertise in diverse sectors, consistently demonstrating progressive levels of responsibility and leadership. Reputation built on driving operational efficiencies through effective utilization of Lean Six Sigma principles and methodologies. Adept at collaborating across functional business units and departments to successfully achieve business objectives and goals.
Overview
15
15
years of professional experience
1
1
Certification
Work History
Small Business Owner/Operator
SaltyLivingHome LLC
01.2023 - Current
- Manage and operate home improvement and outdoor hardscapes business
- Responsibilities include setting business goals and strategy that result in business growth, brand recognition, and desired profit margin
- Hire and train employees, and create a quality culture that results in high customer satisfaction
- Manage company expenses and all other aspects of the business
Process Engineer III
Wells Fargo
01.2021 - 01.2023
- Consult business functional leaders
- Responsible for developing, improving, and optimizing business processes, solving critical customer and business challenges, and driving measurable performance improvement while ensuring adherence to policy, regulatory, and compliance guidelines
- Support the front office and middle office process redesigns, transformations, and high-risk initiatives that are considered a high priority by the company
- Create and maintain Risk and Control Self-Assessment (RCSA) Service Models. This includes partnering with stakeholders across the organization and performing data gathering, review, and facilitation of the production of the RCSA Service Models
- Achieved RCSA service modelling goal for 2021, 20 services modeled and formally documented
Lean Sensei
Atrium Health
01.2018 - 01.2023
- Consult Healthcare business functional leaders in planning, executing, and oversight of the implementation of performance improvement strategies utilizing Lean methodology to achieve the annual strategic goals and objectives of the organization
- Responsibilities include fostering, developing, and strengthening executive relationships
- Solving critical customer and business challenges, and driving measurable performance improvement
- Facilitate rapid improvement workshops, provide training, and coach and mentor functional area leaders and staff
- Silver Beacon award – RN bedside report handoff process, Maternity unit, Pineville NC
Logistics and Procurement Group Manager
Caterpillar Inc.
01.2021 - 07.2021
- Provide leadership and manage the Logistics Planning team
- Responsible for the creation and optimization of raw material component replenishment processes to improve the delivery and flow of materials from suppliers to the point-of-use
- Collaborate with suppliers and facilitate projects that drive accurate and timely delivery of raw material components to achieve desired inventory targets and service
- Collaborate with 3rd party on-site paint provider and coordinate daily paint requirements for components to achieve daily operational goals
- Developed pull processes to reduce point-of-use inventory
Six Sigma Black Belt
Caterpillar Inc.
01.2017 - 01.2021
- Consult with business functional leaders to identify and execute performance improvement projects utilizing the Six Sigma DMAIC methodology and Lean principles within the manufacturing facility
- Championed the adoption of Lean Six Sigma methodologies within the department, driving a culture of continuous improvement.
- Identify, train, and certify facility Green Belts
- Facilitate rapid improvement workshops/Kaizen to improve operational processes, and implement standard work
- Reduced operational costs with the implementation of Lean Six Sigma methodologies.
- Co-developed the Supply Chain Performance Engineer role for the Caterpillar Building Construction Products Division with McKinsey & Company consulting management group
- Certified Six Sigma & Lean Caterpillar Production System Black Belt
Lean Operations Manager
Cardinal Health
01.2016 - 01.2018
- Consult with facility leadership to identify and execute performance improvement projects utilizing the Six Sigma DMAIC methodology and Lean principles within the manufacturing facility
- Led process improvement initiatives that resulted in reduced costs and increased operational efficiency within the kitting assembly operations department.
- Production efficiency improvement project – 5% efficiency gain realized
- Provided exceptional training and mentorship to facility staff and employees, fostering a culture of continuous improvement within the team.
- Increased operational transparency by creating detailed reports on key performance indicators for senior management review regularly.
Director, Supply Chain Planning
Cardinal Health
01.2014 - 01.2016
- Work with executive leadership to achieve cost, quality, and customer service goals for the Presource hospital surgical pack division by providing leadership and overseeing the procurement of raw material components and inventory planning and strategies
- Boosted operational efficiency by optimizing supply chain processes.
- Established a culture of continuous improvement by fostering open communication channels and empowering employees to voice their ideas.
- Facilitated cross-functional collaboration for improved decision-making processes within the organization.
- Increased company revenue by streamlining processes and implementing cost-saving measures.
- Standardization and centralization of 3 plant purchasing departments
- Implemented performance metrics for consistent evaluation and improvement.
- Reduced average weekly substitution rate by 53%
Materials Manager
Cardinal Health
01.2012 - 01.2014
- Consult with the facility director, controller, and operations managers on all aspects of facility operations to achieve facility cost, quality, and customer service goals for sterile and non-sterile hospital surgical packs.
- Responsible for 4 department supervisors for the procurement and on time delivery of raw material components, daily release of work orders, finished goods inventory levels, and customer service levels.
- Additional responsibilities include management of 3rd party sterilization provider, 3PL short haul provider, and cross dock operations to support 70 distribution centers across the continental north and southeast regions.
- Negotiated 3PL short haul contract - $200k annual savings
- Coordinated with production planning teams to ensure timely availability of raw materials required for scheduled productions runs.
- Communicated regularly with suppliers to uphold accountability for quality standards and timely delivery of goods.
- Developed and tracked metrics to measure supplier performance and cost savings - supplier scorecard.
- Achieved 99.6% customer service level
Material Planning Supervisor
Caterpillar Inc.
01.2010 - 01.2012
- Provide leadership, supervision, and mentor the Material Planning team for the timely delivery of raw materials to support assembly operations, and minimize inventory surpluses and shortages.
- Oversee the inventory accuracy team to ensure accurate inventory balances are achieved, cycle counts performed, and inventory adjustments completed in a timely manner with root cause analysis.
- Established a culture of accountability within the team by setting clear expectations and monitoring performance metrics closely.
- Championed continued education within the department, fostering a culture of growth and development among team members.
- Conducted regular performance evaluations for staff members, driving continuous professional development.
- Collaborate and manage the supply base to minimize and resolve material delivery issues
- Developed and maintained strong relationships with stakeholders, ensuring clear communication of expectations and progress updates.
Education
Master of Business Administration -
Eastern New Mexico University
Portales, NMBachelor of Science - Business Administration
North Carolina Wesleyan College
Rocky Mount, NCSkills
- Small business operations
- Planning and execution
- Vendor relations
- Inventory management
- Delegation
- Process improvements
- Performance improvement
- Teamwork and collaboration
- Project management
Certification
Certified Lean & Six Sigma Black Belt, Caterpillar, Building Construction Products Division
Timeline
Small Business Owner/Operator
SaltyLivingHome LLC
01.2023 - Current
Process Engineer III
Wells Fargo
01.2021 - 01.2023
Logistics and Procurement Group Manager
Caterpillar Inc.
01.2021 - 07.2021
Lean Sensei
Atrium Health
01.2018 - 01.2023
Six Sigma Black Belt
Caterpillar Inc.
01.2017 - 01.2021
Lean Operations Manager
Cardinal Health
01.2016 - 01.2018
Director, Supply Chain Planning
Cardinal Health
01.2014 - 01.2016
Materials Manager
Cardinal Health
01.2012 - 01.2014
Material Planning Supervisor
Caterpillar Inc.
01.2010 - 01.2012
Bachelor of Science - Business Administration
North Carolina Wesleyan College
Master of Business Administration -
Eastern New Mexico University
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