SUMMARY

Process-oriented manufacturing professional with 30+ years of increasingly responsible leadership experience, consistently demonstrates proven results in project management, plant and department operations, financial reporting, and safety improvement. Skilled in achieving high OEEs through proper use of training, innovation, and standard operating procedures. A versatile, people-oriented manager and team builder with proven success in safety, quality improvement, and customer service areas. 

AREAS OF EXPERTISE

• Operations Management
• Project Management
• Production Scheduling
• Safety Management
• Inventory Control
• Plant Management

PROFESSIONAL EXPERIENCE

Confidential, Dyersburg, TN 2008 – 2011
Plant Director, Dyersburg Plant
Oversaw all plant operations for a powder laundry detergent manufacturing plant. Directed overall safety programs, quality, OEE improvements, leadership development, environmental compliance, and approval and oversight of $16 MM yearly budget.

• Added blow mold and stretch mold operation that produces over 7,000,000 bottles per month in 2008.
• Implemented and oversaw the movement of 650,000 cases from another plant to Dyersburg with an additional 60 employees hired; realized a $2.6M per year savings. This increased cases produced from 700,000 to 1,300,000 per month.
• Controlled expenses, increased production, and saved $1.2M in operating costs the first half of 2011.
• Maintained a low hold rate for 2010 at 0.09%, the lowest in the company.
• Improved safety in the plant from 20 OSHA recordables in 2008 down to 3 in 2010 by creating a safety culture that was driven by the associates.
• Awarded a very low union risk aversion benchmark by a third party assessor; held plant meetings on a monthly basis, small plant director meetings with all associates through the year; established protocol requiring managers to spend time in work areas and interact with associates.
• Achieved highest OEE in the company for newly-constructed blow mold department; reduced operations from 7/24 to 5/24 operation.
• Successfully transitioned the plant from Huish Detergents to Sun Products Corporation in September 2008.

Confidential., Dyersburg, TN 1988 – 2008
Director, Manufacturing, Dyersburg Plant 2005 – 2008
Challenged to direct all manufacturing operations in the plant including safety, quality, OEE, personnel changes and improvement, annual reviews for all affected employees, yearly budgets, monthly review of budgets to insure all departments were under budget and capital project budget for the next year. Oversaw all improvements to the manufacturing departments, and implemented changes in procedures as needed.

• Improved OEE of the powders department; converted from a 7/24 hour schedule to a 3 ½ day schedule. This was accomplished by:
• Creating a changeover team to improve changeover time.
• Removing fully automatic case packers and replacing them with semi-automatic case packers as the automatic case packers were not changeover friendly.
• Harmonizing formulas to 1 base formula to allow the processes to run more efficiently.
• Unifying the powders area from 3 production departments to 1 production department. This reduced supervisory staff and increased flexibility on the packaging lines.
• Aligned labor and overhead costs with all other plants, achieving harmonized costing across the company and true costs that were balanced with budgets.

Production Manager, Confidential 1995 – 2005
Managed all manufacturing operations in the plant including, Lows Suds, Automatic Dish, and High Suds departments. Monitored production areas to insure personnel complied with all safety rules and regulations, improved OEE, maintained and prepared employee records, insured all products were produced to quality specifications, scheduled production to meet all customer demands. Submitted budgets every year and stayed within budgets on a monthly basis.

• Assisted with design and commission of an Automatic Dish Detergent system with a new agglomerator and packaging lines.
• Worked with corporate engineering to resolve hydration issues with the phosphate system.
• Selected as project lead for the installation of a spray tower and 2 more production lines.
• Assumed responsibility for the maintenance area to improve reliability in the plant. Implemented the use of a maintenance program (MP2) to control and monitor all maintenance functions.

Production Supervisor, Confidential 1988 – 1995
Recruited to supervise assigned shift and meet production schedules for Automatic Dish Detergent department. Verified packaging and chemicals for the next shift, coordinated with maintenance for line changeovers and needed repairs, maintained and prepared employee records, insured all safety procedures and rules were followed, insured all products were produced to quality specifications, and insured all training for operators was completed as per the training manual.

• Wrote training manual for the department.
• Improved OEE in the department to insure that all customer demands were met.
• Successfully passed a Lever Brother Quality audit 4 times.
• Commissioned a new vibratory fluid bed.

EDUCATION

Accounting, Confidential College

TECHNICAL SKILLS

MS Office including Excel, Word, Power Point and Outlook