Tony Shacklady

Development of products and processes for North American Market. • Continue to support and maintain responsibility for the Jacketing section. • Develop efficient, cost effective products and processes. • Plans, implements and tests production systems and processes to ensure an optimized product. • Harmonize all products and process throughout the manufacturing in US, India, Italy and other STL OFC plants.

Managing a startup green field Fiber Optic company in the USA. (Responsibilities: Jacketing and Rewind) • Commissioning, development and procurement of equipment. • Training of both the engineering technicians and operators. • Supporting Quality; Stranding; Buffering and all other production sections for the USA market.

Managed / developed key new products. Significantly reduced product costs with material reduction and alternative technology. • Project management and commissioning of two new high speed production lines within an aggressive timeline. The OEM did not deliver the equipment or results as promised with the first line, but we did! Second line performed as expected. • Submitted three Product Improvement Plans ~ demonstrated their performance and will save over $11 million by 2023. • With material / labor shortages, and logistic nightmares. Products were developed and qualified at unprecedented rates.

Process engineering and development to ensure a quality, repeatable, efficient product/process • Designing and implementing revolutionary equipment for process robustness and reduced costs • Enhancing safety and reducing maintenance down time issues • Identified and proposed patent-able ideas to meet and enhance portfolio for a growing market

Cable development and new product introduction (NPI) • Developed key processes and equipment for a number of new products. • Managed projects from design conception to commissioning of new equipment and training of personnel including a project achieving triple manufacturing line speed and half material cost.

Maintained and developed new processes and products • Successfully developed a new test method to measure EFL/ERL in the cable form, which resolved some major cable failures • Developed and tested with R&D, a new cost effective material which will reduce production costs by over 20%

Design and development, of optical fiber communication and copper premise cables • Successfully developed several new cost effective products and submitted a number of patent-able fiber/copper applications • Designed and developed process equipment to modify/enhance copper cable performance • Evaluation of competitor cables, and assisting other manufacturing facilities in the reduction of process defects

Met customer demands through the implementation of new or alternative processes, technology and materials • Significantly reduced wire breaks by process improvement and through direct involvement with the copper supplier • Introduced a cost effective materials for X’web production, leading to a cost reduction of over 10% • Developed equipment to enable injection foaming, with a calculated annual saving of over $1 million

Project management and development of key new product families to enhance the product portfolio • Successfully developed, industrialized a new product with innovative design, drawing new clientele, increasing market share and becoming a mainstream product, with reduced operational costs by over 20% • Successfully introduced and applied new processing techniques that both reduced costs and improved productivity.

Management and development of key processes • Successfully developed, industrialized, patterned and controlled the full implementation of a new cost effective product, material saving of over 50%, increased productivity (3 fold and more) • Significantly, improved efficiency of other product families through the application of Kaizen philosophy, Lean manufacturing techniques and reduce manufacturing costs through sourcing and supply evaluation. • Facilitator of over three QC teams. Team leader of the a QC team which saved of over $300K/y by engineering a solution to a major problem • Managed and directed nine engineering staff in the support of the buffering, stranding and the fiber-coloring departments, significantly increasing productivity and reducing operational costs in all three departments

Management of major process development projects for America and Europe • Introduced design of experiment methods as standard to establish optimum process conditions • Managed and co-coordinated a number of technicians for production prototypes • Worked cooperatively with operators in best practice and process enhancements • Defining, procuring and commissioning new manufacturing equipment with values from $40k to $900K • Played a key role in launching a cost effective Loose Tube product. This led to over 60% productivity improvement