Raul Pomales is an experienced Lean Six Sigma expert with over 30 years of experience. He currently works as the Business Excellence Lead at Johnson & Johnson in Ireland, where he leads Lean Six Sigma projects and coaches green and black belts. Previously, he held similar roles at Schering-Plough and Tyco, delivering millions in savings. Pomales has a degree in electrical engineering and is a certified Lean Six Sigma Black Belt with experience in DMAIC, DFSS, and other methodologies.

1. Name: Raul R. Pomales Pomales
Address: 4, Hermitage Drive, Rushbrooke Links, Cobh, County Cork, Ireland
Phone No: ++ 353 (0)87 1415745 (cell/mobile)
++ 353 (0) 21 4812987 (Home)
Status: Married to Irish citizen, USA citizen/passport holder
Highly motivated and goal orientated engineering/Lean Six Sigma professional with a
track record of consistently exceeding project target expectations completion. Proven to
provide internal leadership/external support in Test/Quality control, Quality Assurance,
Product/Project technology transfers, procedural improvements and developing
test/operational methodology. Use of Project Management skills to transfer, outsource
and assist third parties development in order to lower product, process and labour
costs.. Successfully led and trained multiple project teams through Lean Six Sigma
(DMAIC) , Toyota Production System- A3 thinking and DFSS ( DMADV) methodologies
to closure and subsequent sustainability within Operational manufacturing sites of
responsibility while working with multiple design centre groups as required, in order to
reduce non value added activities while achieving project goals.
Skill Set summary:
- Honours Degree Bachelor of Science in Electrical/Electronics Engineering.
- Practitioner on mentoring and facilitating using HPO( High Performance
Organization), CEM (Change Execution Methodology) and BCCM
( Behavioural Coaching & Consequence Management ) methodologies/tools
following Conner Partner guides and techniques
- Certified Black Belt DMAIC Six Sigma/Lean ( Tyco & Merck Sigma)
- Green Belt DFSS (DMADV) Six Sigma/Quality Function Deployment ( Tyco &
Merck Sigma)
- Project Leader/Facilitator of Lean/Six Sigma Manufacturing strategies
- GMP and ISO 9000 deployment and implementation with exposure to FDA
regulations, awarded FDA/FAS Certificate on May 7th
. 2009
- Internal/External Lead Assessor on ISO standards deployment
- Total Quality Management tools and standards used on Supplier Qualification,
New Product Introduction and Process/Equipment transfer
- Extensive use on Project management tools and techniques on
directing/facilitating multiple project teams including Financial/Productivity
Risk analysis
- Team leader and Facilitator while observing/deploying HR regulations as
applicable in High volume Electronics/Assembly manufacturing operations
- Use of associated Industrial engineering tools on layouts, standard times,
ergonomics and tool deployment as needed

2. _____________________________________________________________________________________
2013- Present Johnson & Johnson, LI (SM) & Ringaskiddy (LM) sites, Cork
Business Excellence Lead, Lean Six Sigma/MBB
Responsibilities
___________________________________________________________________________________
- Opex LMD System Lean Six Sigma leader/Facilitator
o Program facilitator on both sites under the eight pillars of J&J operations
o Global BEx representative on sites Metrics and project deployment
o Site Operations Team member
- Site Master Black Belt managing and coaching Six Sigma project selection process
o Ensure projects begin and remain aligned with organizational strategic CTQ’s-
KPI’s ( Training requirements inclusive)
o Act as stakeholder/sponsors mediator or conflict negotiator on project teams
risks as necessary
o Monitor and counselling of project teams at review of key measure and data
collection plan using key lean tools as needed.
o Facilitate team building, focusing on conflict resolution and decision making if
project team members dispute data or other process step via CEM and BCCM.
o Mentor of 12 Green Belts, 3 Black Belts using DMAIC, Kaizen and training of
advanced Lean manufacturing techniques following Toyota principles in
alignment with J&J Operation system
Key Achievements:
- Value stream mapping of key sterile products highlighting areas of improvement
(Equipment reliability-TPM/OEE, Risk reduction projects, Right the First Time
metrics) via Kaizen activities with Sponsors and Stakeholders
- Champion/Leader of Six Sigma Council and program deployment at site
facilitating, coordinating, executing projects with/by
o 1 Black belts certified by J&J Global BEx delivering 1.5MM savings
o 5 Green belts certified by site BEx projects delivering avoidance of € 2.5
MM for 2014
- Coach at Little Island site on Lean Manufacturing deployment and Assessment
to a “High Pull Level” under J&J criteria ( 360 colleagues)
- Coach at Ringaskiddy site on Lean Manufacturing deployment and Assessment
to a “Med Pull Level” under J&J criteria ( 520 colleagues)
- Facilitation and Coaching on Statistical analysis on KT investigations for OOS
OOT compliance investigations (5x)
- Trained/Certified 120 colleagues on Yellow Belt techniques and Root Cause
Problem solving following “Lean Thinking”
- Continued Process verification system deployment under ICH-6,7,8 guidelines at
Little Island site.
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3. 2009 –2012 Schering Plough/Merck Manufacturing Division,
Brinny, Innishannon, Cork Ireland
Position: Site Lean Six Sigma leader/ Master Black Belt
_______________________________________________________________________
_
Responsibilities
- Merck Production System Lean Six Sigma leader/Facilitator
o Project facilitator on 2 Sterile Business units consisting of Parts Prep, media
Compounding, bottle Filling process, Lyophilisation, packaging and labelling
and Batch Record streamlining with process standardization activities
- Site Master Black Belt managing and coaching Six Sigma project selection process
o Ensure projects begin and remain aligned with organizational strategic CTQ’s-
KPI’s ( Training requirements inclusive)
o Act as stakeholder/sponsors mediator or conflict negotiator on project teams
risks as necessary
o Monitor and counselling of project teams at review of key measure and data
collection plan using key tools as needed.
o Facilitate team building, focusing on conflict resolution and decision making if
project team members dispute data or other process step via CEM and BCCM.
o Mentor of 24 Green Belts, 5 Black Belts using DMAIC, Kaizen and training of
advanced Lean manufacturing techniques following Toyota principles in
alignment with MPS
Key Achievements:
- Introduction of Materials Vendor Managed Inventory and KANBAN system to
support 4 different laboratories sections, 8 sterile value streams, engineering
spare parts with benefit of €800k per year and value streams down time
reduction of 15%
- Leader of 5 different Kaizen’s on Sterile business unit to achieve a transition
from 4 shift 7 days to 3 shift 5 days via work standardization reducing non value
added activities that drove economic direct savings of €1.2 MM/year in 2010
with realisation on 2011.
- Mentor and Coach of RM/SQA labs lean team to reduce cycle time from 42 to 20
days with economic impact of €250k in 2011
- Mentor and Facilitator of Chemistry/Biological QA labs to standardise work
activities which resulted in a cycle time reduction from 40 days to 17 days
realising €275k/year savings and increased capacity of 25% to accommodate
external labs activity without adding FTE’s
- Value stream mapping of key sterile products highlighting areas of improvement
(Equipment reliability-TPM/OEE, Risk reduction projects, Right the First Time
metrics) via Kaizen activities with Sponsors and Stakeholders with savings result
of €9.7 MM/year in 2012
- Champion/Leader of Six Sigma Council and program deployment at site
facilitating, coordinating, executing projects with/by
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4. o 4 Black belts certified by Merck Sigma delivering 3.5MM savings
o 9 Green belts certified projects delivering savings of € 2.5 MM for 2012
o Training matrix schedule Teacher for Lean Problem Solving ( Toyota
DNA based) that cover 160 operators as Yellow Belts Certified- to sustain
site competitiveness
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2002 -2009 Tyco Safety Products, Melbourn Road, Cork Ireland
Position: - Senior Product/Process Engineer
- Operational Site Black Belt, DMAIC, Facilitator/Mentor/Coach
Responsibilities
- EMEA Sensormatic Retail Solution Team leader on Low Cost programs
o Project manager of related process improvement or product re-design site team
o Interface with 3 Global Design centres and Manufacturing operations sites on
Product cost reduction programs
o Inditex Store Chain Customer/Field Engineering VA, Spain
o Facilitator on Product transfer & Introduction of Fire and Detection ( to UK
design Centre, Birmingham) products using and deploying and training of
advanced Lean manufacturing techniques
- Product/Process engineering support of 6 different manufacturing cells, 64 operators, 3
team leaders. ( Multi layered electronics, different Mechanical applications, Plastic
Vacuum forming, Heat seal, adhesive deployment and final product segregation using
DFM/DFT tools
- Customer Engineering Liaison of direct Product line end user
Key achievements:
- DMAIC Black Belt Six sigma and Lean Manufacturing Certification
- Project Leader ship of 6 different Operational and Process Six Sigma teams delivering
savings of $750K EIBT/year with impact of $1.5M at EMEA SBU level FY07/08
- Coaching ,training an Certification of 6 Green Belts leading to $450K EBIT/yr. thur
various product lines FY 06/07
- EMEA Engineering lead of Electronic Article Surveillance on Customer support and
end product deployment through out Spain, Inditex Stores Chain and in particular
with TEMPE manufacturing operations based in Alicante, Spain
- Member of EAS Label Products Global Team, as Ireland Team Leader, achieving 11
% final product cost reduction by Lean manufacturing deployment at Cork IRE
manufacturing site
- Leader on Lean Engineering and technical innovation deployment projects throughout
different assembly processes delivering $650K EBIT for FY05-06
- Introduction of 5 Electronic Article Surveillance products with associated Supplier
qualifications and Process development and implementation.
- Justified and submitted 3 tool and operations redesign to IDA achieving grants
Qualification of $ 360K that sustained EAS Global deployment to Shenyang Tyco
Operational site, China. Final savings to European SBU equivalent of $1 .2 M EBIT/yr.
- Selected Tyco TSP-Shenyang Cork IRE site Representative for CCIB-CCIC Europe
V.B., China Governmental Interface POC signature on Product and Processes Transfer
needs assessment and deployment.
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5. Employment
2013-Present Johnsson & Johnsson, LI & Ringaskiddy sites, Cork
Business/Ops Excellence Lead, Lean Six Sigma/MBB
2009 – 2012 Schering Plough/Merck Manufacturing Division,
Brinny, Innishannon, Cork Ireland
Site Lean Six Sigma leader/ Master Black Belt
2003 – 2009 Tyco-TSP, Sensormatic Electronics Ireland LTD, Melbourn
Road, Bishopstwon, Cork, Ireland.
2007 – 2009 Senior Product/Process/Test Engineer EAS product EMEA.
2006 – 2009 Certified Six Sigma/Lean Black Belt level site Team Leader
2003 – 2006 EAS Product/Process/Test Engineer
1987 – Mar 2002 Sensormatic Electronics Inc., Aguadilla, Puerto Rico-USA
1999 – 2002 Strategic Engineering & Technical Innovation Director
1996 – 1999 New Product Introduction & Technical Services Director
1994 – 1996 Manufacturing, Process/Test Engineering & New Product Introduction Director
1989 - 1994 Quality Assurance Manager, Promoted to Director
1987 – 1989 Test/Quality Engineer
1985 – Apr 1987 Storage Technology Corporation, Mayaguez, Puerto Rico
1985 – 1987 Process/Test/Quality Engineer
Education and Major Certificates
2014 “ Statistical Tools for Pharmaceuticals” Minitab ver 17.2
2011 Lean Practical Problem Solving, University of Kentucky-TEMA,
Galway
2010 Toyota Production system (TPS) related
Lean Science Training-TPS Way, Ydatum-TEMA,
Lean Leadership/Thinking Work Shop, UCC
2010 Principles of Bio processing, NIBRT/ DCU
Biologics GMP Guides and regulations, Merck Mfg Div., Brinny
2009 FAS/FDA Training and Certificate, Cork , Ireland
2006 Tyco/TSP DMAIC Lena Six Sigma BLACK Belt certification,
Cork , Ireland
2005 Tyco/TSP DFSS ( Design for six sigma ) Green Belt certification,
Cork , Ireland
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6. 1994 ISO Internal Lead Auditor Certification, Quantel Fla., USA
1980 -1986 University of Puerto Rico ( CAAM),
Mayaguez
BSEE Honours Degree ( Digital Electronic Control systems)
Minor: Physics/Maths
1975- 1979 San Antonio High School, Guayama , Puerto Rico
PC literacy
BaaN/VI, MRP I and II. All Microsoft related programs commonly used ( PP, Excel,
Word, Access, Project Mgnt) Pro-E,OrCad, Sigma Flow, AutoCAD, Minitab XV ( Six
Sigma statistical tool with Quality companion 3 for Value Stream Mapping), Design of
Experiments at different grades, Power Steering ver 8 project management database
system
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7. 1994 ISO Internal Lead Auditor Certification, Quantel Fla., USA
1980 -1986 University of Puerto Rico ( CAAM),
Mayaguez
BSEE Honours Degree ( Digital Electronic Control systems)
Minor: Physics/Maths
1975- 1979 San Antonio High School, Guayama , Puerto Rico
PC literacy
BaaN/VI, MRP I and II. All Microsoft related programs commonly used ( PP, Excel,
Word, Access, Project Mgnt) Pro-E,OrCad, Sigma Flow, AutoCAD, Minitab XV ( Six
Sigma statistical tool with Quality companion 3 for Value Stream Mapping), Design of
Experiments at different grades, Power Steering ver 8 project management database
system
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