Steven K. Blair
Food Safety/Quality Assurance Manager
Newport,KY
Summary
- U.S. Navy Veteran with over 10 years leadership, project management, operations management, food safety and warehouse distribution experience
- MBA graduate – Benedictine University, Lisle, IL
- Toyota Motor Sales Kaizen Facilitator with extensive scope of responsibility and track record of delivering optimal results in high-growth environments
- Certified Six Sigma Black Belt – Villanova University
- Certified Quality Auditor – ASQ
- Precise Quality Assurance Manager proficient in all QA operations, policies and procedures
Overview
3
3
Certificates
7
7
years of post-secondary education
32
32
years of professional experience
Work History
Food Safety/Quality Assurance Manager
Castellini Company
Wilder, KY
04.2018 - Current
- Monitored staff organization and suggested improvements to daily functionality.
- Recorded, analyzed and distributed statistical information.
- Implemented new quality assurance and customer service standards in QuickBase. Reduced paper documentation by 95%.
- Specified quality requirements of raw materials with suppliers. Ensured 100% compliance with FSMA and COSTCO traceability requirements.
- Inspected inbound and outbound products for compliance with established industry standards, company policies and procedures.
Managing Member
Aria Consulting
Walton, KY
02.2017 - Current
- Helped clients plan and implement food safety and Customs-Trade Partnership Against Terrorism (C-TPAT) strategies.
- Certified ASQ Quality Auditor.
Quality Manager
Perfetti Van Melle, PVM
Erlanger, KY
03.2015 - 02.2017
- Led and managed 3 salaried supervisors and 12 hourly associates.
- Developed strategic action plans in support of PVM business objectives.
- Authored and implemented PVM USA’s Foreign Supplier Verification Program, ensuring all importers were compliant with FDA regulations and C-TPAT guidelines.
- Led breakthrough quality improvements for Airheads, Xtremes, and Mentos brands.
- Developed statistical analysis to improve quality & manufacturing productivity.
- Implemented Kaizen culture across 3 departments, resulting in improved processes, waste reduction and over $300K in savings.
- Primary liaison with FDA, third party auditors, and regional food safety authorities.
- Audited external warehouses, co-packers and suppliers for compliance with FDA regulations.
- Perfetti van Melle, Brazil – conducted C-TPAT gap analysis.
Assistant Operations Manager
Toyota Motor Sales, Toyota
Hebron, KY
06.2012 - 03.2015
- Toyota's 843K square-foot distribution center employs 370 associates and receives and stocks $42K repair and service parts from more than 375 North American suppliers.
- Led and managed 3 front line supervisors, 83 hourly associates, and $10K department operating budget to consistently exceed Key Performance Indicators (KPI’s).
- Ensured production KPI achievement, and adherence to safety, security and quality procedures.
- Developed department annual plans and aligned resources to ensure completion.
- Authored business cases that awarded $250K in capital funding for ergonomic improvements.
- Led high performing Kaizen Teams in business process improvements.
- Examples of team successes included:.
- 56% improvement in department ergonomic scores and process efficiency by implementing powered picking platforms and installing skate wheels or tight wire for all locations with parts over 40 lbs.
- 35% improvement in department order processing time by implementing small batch processing, accurate cycles and standards, and progress control boards for all department production processes.
- 42 % reduction in department picking errors by implementing simplified standard operating procedures, piece by piece scan for multiple quantity orders, and quality audits.
- 50% reduction in daily receiving dock freight dwell time by implementing FIFO system and kanbans.
- Implemented weekly 5S audit walk-thru across all divisions.
- Selected to mentor and onboard management trainees:
- Developed leadership curriculum, and 6-month training plan.
- Shared best practices with peers throughout corporate network.
Operations Leader
Toyota Motor Sales
Aurora, IL
05.2007 - 06.2012
- Supervised 32 hourly associates and 4 contingent associates during shipping and receiving operations in a 300K square-foot distribution center.
- Ensured daily production goals were met and adherence to safety, security and quality procedures.
- Spearheaded Kaizen teams and Jishukens to improve business processes and ensure optimum performance.
- Managed project resources and timelines with the following results:.
- Reduced picking errors by 30%, an estimated $65K in annual savings.
- Redesigned the shipping dock layout and created a more efficient shipping process, saving an estimated $28K/year.
- Utilized excel spreadsheets, and heijunka historical data to project daily inbound parts shipment and adjust workload forecast.
- Utilized databases and Toyota's Warehouse Management System to track associate production to meet shift deadlines.
- Developed and implemented facility priorities and annual plan.
E-8/Engineering Program Manager
U.S. Navy
08.1992 - 06.2007
- Directed training staff of 25 instructors, 13 civil service employees, and 14 union contractors in administration of Naval Military Training, and Student Indoctrination.
- Led 52-personnel ship firefighting and damage control team in preparation for deployment during Operation Iraqi Freedom – cross-trained personnel, lending greater flexibility during ship emergencies.
- Supervised initial installation and testing of over $20M in propulsion equipment.
- Led division of 31 engineers through $5M, four-month shipyard industrial availability in which all main propulsion and auxiliary support equipment were disassembled, repaired and tested.
- Consistently maintained lowest rework levels among 5 engineering divisions.
- Implemented in-depth elevator/conveyor training and safety inspection program, resulting in zero safety mishaps over 2-year period.
- Evaluated existing procedures and made proactive adjustments to meet changing demands
Education
MBA - Organizational Leadership
Benedictine University
Lisle, IL 06.2007 - 11.2011
Bachelor's Degree - Workforce Education And Development
Southern Illinois University Carbondale
Carbondale, IL 06.1998 - 05.2001
Skills
Inventory and WMS expert
undefinedCertification
Certified Quality Auditor
Timeline
Certified SQF Practitioner
12-2019
Certified Advanced HACCP
11-2019
Food Safety/Quality Assurance Manager
Castellini Company
04.2018 - Current
Certified Quality Auditor
11-2017
Managing Member
Aria Consulting
02.2017 - Current
Quality Manager
Perfetti Van Melle, PVM
03.2015 - 02.2017
Assistant Operations Manager
Toyota Motor Sales, Toyota
06.2012 - 03.2015
MBA - Organizational Leadership
Benedictine University
06.2007 - 11.2011
Operations Leader
Toyota Motor Sales
05.2007 - 06.2012
Bachelor's Degree - Workforce Education And Development
Southern Illinois University Carbondale
06.1998 - 05.2001
E-8/Engineering Program Manager
U.S. Navy
08.1992 - 06.2007
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