SENIOR MANUFACTURING MANAGER

A technically sophisticated manager with a broad manufacturing background, including experience with manufacturing fire protection products, paper gaming products, printing, and rubber hose for the automotive and airline industry. Proficient at leading manufacturing groups to achieve goals consistent with the reduction of waste, improving the effectiveness of equipment, operators and supply chains, and improving overall corporate profitability. Consistently improved profits by managing projects and improving performance in areas that were previously problematic.

PROFESSIONAL HIGHLIGHTS

• Continuous Improvement - Drove lean and six sigma projects that were implemented to increase customer satisfaction and improve upon the customer’s three main areas of concern, which included reducing overall lead times, improving on-time shipping performance and reducing certain reoccurring quality defects. Utilized Value Stream Mapping to eliminate non-value added elements of the production process, effectively reducing lead times for all product lines by nearly 50%. Increased on time shipping performance from less than 70% to over 95% by implementing a pull production system, using Kaizen events to identify the production bottleneck and improve flow in that area, utilizing spaghetti charts to reduce travel time and the introduction of automated processes to improve overall production time. Developed strategies to improve customer satisfaction by eliminating critical product quality deficiencies by utilizing Kaizen events, poka-yoke devices, and standardization of work. This resulted in the reduction of specific quality defects by 85%. Improved work flow by eliminating stand alone inspection stations and incorporating progressive inspections into the production processes. Also utilized 5S, visual work environment and SMED techniques to reduce waste.
• Automation - Recently procured automated equipment that resulted in a labor savings of $400,000 annually. Oversaw the installation of an offset press with automatic plate hanging capabilities as well as digital printing equipment that eliminated 8 production positions. Purchased and installed automated pre press equipment that improved efficiencies and allowed the plate production process to be completed in one shift as opposed to the previous three shifts that were required. This resulted in labor savings of about $100,000 annually.
• Inventory Control - Linked with the supply chain to implement just-in-time deliveries so that raw material inventories were reduced to a minimal level. Utilized pull techniques to reduce work in process inventories. Developed a plan in conjunction with the Sales and Marketing to reduce finished goods inventory levels. Allowed a predetermined inventory level of certain stock products based on the average number of annual inventory turns for the stock products, production of finished goods inventory was eliminated for all other product groups. This program eliminated finished goods inventory levels from $3,500,000 to $1,000,000 over the past five years.
• Labor Relations/Human Resources - Saved approximately $250,000 by negotiating with the Union to freeze and eventually terminate a pension plan that had been in place since the 1970’s. This pension was replaced with other benefits that were more cost effective. Effectively reduced health insurance expenses by 30% during the last policy renewal by making changes in plan options, this resulted in a savings of $420,000. Negotiated the last 4 Union contracts. The last two contracts resulted in wage freezes, spanning eight years.
• Purchasing - Negotiated pricing decreases for paper, corrugated, cutting dies, printing plates, hazardous waste removal, freight, and small package shipments that resulted in an average decrease in expenses of 10% in 2009.

CAREER PROGRESSION

Confidential 5/2010 - Present

Production Manager

Manage Production operations for Standard Products production line, which includes about 200 employees and generates approximately $100,000,000 in annual revenue. The Standard Product line produces a variety of hand held portable fire extinguishers, restaurant fire extinguishing systems, gas station fire extinguishing systems, and military and commercial vehicle fire extinguishing systems.

• Implemented Safety initiatives that have significantly reduced the unit’s injury rate. Recently attained a streak of 85 days without a recordable injury, the longest such streak within this operation in the past 5 years.
• Manage 9 separate value streams. Championed 3 lean and 4 5S events since hire date. Currently have 15 events scheduled for this calendar year - 6-5S, 5 - Lean, and 4 scrap reduction projects. The completion of the lean projects have greatly contributed to increasing overall effectiveness of unit from 93% to 96% over the first 5 months of this fiscal year.
• Manage supervisory staff of six production supervisors, five planners, six group leads, and 2 manufacturing engineers.
• Initiated steps to develop a Visual Factory. We now post hourly, daily, weekly and monthly KPI’s, including Safety, Quality, Delivery, and Cost metrics.
• Currently responsible to insure that all supervisory and hourly associates are progressing within our SAP implementation training program.
• Instrumental in improving schedule attainment rate from about 80% to 90%.
• Responsible for the installation and start up of new CNC automated cartridge threading machine that replaced outdated equipment.

Confidential 12/1993 - 11/2009

Plant Manager - 2001-2009

Managed all aspects of the operations of this $30,000,000/yr., 300 employee paper gaming product manufacturer and commercial printer. Responsibilities include the following:

• Developed and analyzed corporate budgets. Directly responsible for the profitability of the operation.
• Lead inventory control programs designed to optimize finished goods and work in progress inventory.
• Guided the procurement of all raw materials and insured that these purchases met budgetary guidelines.
• Justified the purchase of equipment and managed the installation of new equipment.
• Accountable for implementing productivity improvements and maintaining acceptable production levels.
• Responsible for corporate wide quality control for all production operations.
• Developed cost models and managed cost estimating.
• Managed shipping and receiving as well as traffic management.
• Insured compliance with all health, safety and environmental regulations.
• Directed periods of staffing growth as well as coordinating reductions in force.
• Launched new production facilities as well as closed, moved, and consolidated other production operations.
• Managed Human Resources, Employee Relations and all company benefits.
• Managed all Plant and Building Maintenance activities.
• Lead negotiator for the past 4 Union contracts.
• Insured that all production activities are in compliance with various state gaming regulations.
• Developed and implemented Standard Operating Procedures for all production activities.
• Automating production planning and scheduling.
• Developed and implemented a quality control program and quality incentives.
• Instituted a method to track daily shipping performance and achieved significant gains in this area.
• Developed and implemented corporate labor plan and managed operations staffing requirements.

Human Resources Manager - 1998-2001

Managed all employee relations, benefits, and staffing activities.

• Developed and implemented hiring procedures, as we were going through a period of significant growth.
• Created corporate job descriptions for all positions within the company.
• Implemented programs designed to improve employee morale.
• Constructed and implemented a corporate employee handbook detailing corporate policies and procedures.

Industrial Engineer - 1993-1998

• Developed cost models and labor standards.
• Built and implemented a health and safety program.
• Found solutions to a severe worker’s compensation problem. Achieved intended objectives, including lowering worker’s compensation insurance premiums from $500,000 to $50,000 annually in three years.

Confidential- 1990 - 1993

Industrial Engineer

Responsible for classic I.E. functions at this Rubber hose manufacturer, including:

• Equipment justification.
• Development of production standards.
• Performing motion and time studies.
• Cost Estimating.
• Productivity improvement.
• Developing and implementing a safety and health program from the ground up.

Confidential- 1986 - 1990

Navigation Systems Avionics Technician

Received an honorable discharge. Responsible for maintaining radar and radio navigation systems on KC-135, C-130, and B-52 aircraft.

EDUCATION

Bachelor of Science Degree, Industrial Technology, Confidential 5/1989.
Lean Management Certification 12/2009.
Six Sigma Black Belt Certification 2/2010.