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Plant Manager Resume Profile

Tallmadge, OhiO

SUMMARY:

Highly accomplished Operations Management Professional with extensive safety, process engineering, maintenance reliability, commissioning start up and operations management experience across Manufacturing, Oil Gas, and Construction industries. Strong engineering background with Master's degrees in Industrial Technology and Business Administration. Areas of expertise include strategic management, product/process development, quality engineering, high volume manufacturing, supply chain management, and multi-site project management. Experienced in combining people and analytical skills to build trust and integrity towards simplifying operations and elevate business performance. Exceptionally talented at integrating operational activities to deliver outstanding solutions to customers. Highly skilled in process optimization and data driven solutions utilizing Lean Six Sigma methodologies. Excellent ability to recruit, train, mentor and led employees both in union and non union environment. Consistently exceeds business profit and production goals with demonstrated achievements in safety and environmental excellence.

WORK EXPERIENCE:

Confidential

Plant Manager

  • Provide leadership and support to safety, health and environmental programs and initiatives to deliever systems that meet or exceed regulatory and permit requirements in all EHS areas including the OSHA's Process Safety Management PSM and EPA Title V air permitting requirements
  • Participant Leading at OC Next Level Senior Leadership Development Program 12months program
  • Commended for delivering substantially to the overall EBIT to the division in 2012 Vs 2011, exceeded KPI
  • Spearheaded the change in productivity and performance realizing manufacturing gains in 2012 over prior year 2011 by 168
  • Led process optimization initiatives that achieved 34 significant reduction in direct cost per boardft
  • Responsible selection, capital project management, process optimization, staff recruitment and hiring
  • Led the development and initial processing of CO2 as efforts geared towards green house gas reduction project in Owens Corning world wide
  • Collaborated and aligned with business leaders, VP's and strategic customers to deliver all the customer commitments guaranteed during a time of constrained availability material
  • Combined effort with Plant Controller to strategically expand the knowledge of plant key manufacturing leaders on cost
  • Successfully implemented High Performance Organization HPO
  • Masterfully led all waste elimination efforts thus creating an effective lean organization

Confidential

Technical Leader

  • Provide daily leadership by example and accountability aimed at delivering zero employee injuries in the workplace
  • Reliability Work Process - Consultant
  • Identified and focused resources on production schedule and recipe optimization, maintenance and production partnering, and pre job planning to drive outstanding performance on yield
  • Led process and operations team in 2012 to achieve highest productivity with record manufacturing gain in plant history
  • Strategically empowered coordinators and extrusion operators to lead product changeovers as an engagement tool
  • Developed short/long term goals and created a continuous learning environment for individuals in operations
  • Directed efforts and established goals for 2 coaches and 4 coordinators cascaded down to all other production employees
  • Foam Manufacturing Development Coach MLP program
  • Designed and led experimental trial to develop High R CW product
  • Provide Technical Support to North American and Asia Pacific plants
  • Led plant production budget 2012
  • Led process and operations team in 2012 to achieve highest productivity with record manufacturing gain in plant history
  • Led process team to achieve Plant record of 40 direct material substitution and achieved 101 Density Efficiency
  • Led process engineering and quality planning to support launch of new products
  • Managed the Operations team of 24 direct reports to safely meet and exceed production targets and Customer's satisfaction in line with Tenets of Operation to reflect in Key Performance Indicators.
  • Actively promoted HSEC culture and best practices and supported the Process Safety Management PSM initiatives.
  • Coordinated the Productions/Operations teams competency and training requirements.
  • Mentored a Project Engineer and Training specialist to achieve Six Sigma Greenbelt certification and currently mentoring Advanced Engineer in Foam R and D
  • Site Advanced Process Control Administrator.

Confidential

Technical Leader

  • Led team of process and R D Engineers to drive best practice among Foam Business Unit leading to significant improvement in manufacturing efficiency.
  • Led the Facility Process Team in 2009 to the highest productivity and plant uptime in the past 11 years.
  • Achieved 3.7 improvement in production volume above year target despite three months downtime due to blowing agent conversion project.
  • Successfully completed a HCFC conversion in 2010, 45 days ahead of schedule.
  • Designed, championed and led experimental trials that qualified substitute recycle resin that significantly reduced annual production cost by 10 .
  • Led data driven initiatives to enhance optimization of density, throughput rate and yield that made Tallmadge plant reliable and most productive plant in foam business.
  • Successfully led experimental trials to establish specification and define product capabilities for Specialty and Engineered Application products and safer barrier trails
  • Provided process engineering support for commissioning, start-up, and operations of Berstoff Twin Screw extruder as member of Tallmadge Plant blowing agent conversion team.
  • Standardized the procedure for evaluating best production recipes to ease job changeovers that maximize product quality characteristics.
  • Managed and maintained internal ISO audit program and coordinated quality inspection and product release program.
  • Extensive liason with Foam Area Sales Manager to provide outstanding Technical and Quality support to customers.

Confidential

Process Engineer

  • Identified opportunities and led improvement projects in process, quality and productivity
  • Developed process documentation based on best run data and maintained a recipe database that minimized job change time by 22 .
  • As Interim Environmental Leader, managed environmental affairs including permit maintenance and compliance, new permitting, reporting, and liaised with state and federal agencies.
  • Led and supported safety initiatives within manufacturing, including leading documentation of safe work procedures and operating instructions.
  • Performed Process Capability Studies and led projects to improve process capabilities of both standard grade and engineered application products.
  • Facilitated two kaizens that led to production of standard work for manufacturing operations, and also established control plans for processes.
  • Generated product specifications based on plant process capabilities and customer fitness for use, for example engineered application product.
  • Constantly liaised with foam customers to resolve product quality issues and provide initiatives for new product developments.
  • Implemented electronic monitoring of control systems that automatically generate notification at any event of any temperature variation from set point.

Confidential

Manufacturing Engineer

  • Monitored and improved Advanced Process Control model
  • Analyzed process and product data, provided feedback and recommendations.
  • Identified and eliminated special cause variations troubleshooting .
  • Used the six sigma methodology to lead continuous improvement CI teams to:
  • Improve vertical weight distribution of fiber glass board F6 Saving of 126,000
  • Improve piece Job Efficiency of specialized OEM product by 5.2 that resulted in annual savings of 265,000.
  • Prevented product and process issues by auditing and then fixing the process to assure consistency in manufacturing operation.

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