VP/Director of Operations/Manufacturing, GM

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Position
VP/Director of Operations/Manufacturing, GM
Location Confidential
No
Location
North Carolina
Willing to Relocate
Yes
Industry
Mining-&-Metals-Production-and/or-Distribution
Function
GENERAL-MANAGEMENT--CEO/COO/GM
Compensation
$150,000 to $300,000

Resume Summary
Demonstrated ability to transform the efficiency and profitability of single, multi-site, and diverse manufacturing systems. Global experience by leading businesses in the USA, Mexico, and Canada with P&L responsibility. Track record in turnarounds, integrating acquisitions, start-ups, and improving customer satisfaction.

Resume Body      VP/DIRECTOR OF OPERATIONS/MANUFACTURING, GM

PROFESSIONAL SUMMARY

Operations Executive with demonstrated ability to transform the efficiency, profitability, and safety of single, multi-site, and diverse manufacturing systems with solid track record in turnarounds, business start-ups, integrating acquisitions, international business, and improving customer satisfaction. Gained significant experience globally by leading businesses in the USA, Mexico, and Canada, as well as having P&L accountability for multiple sites.

MBA and Lean Six Sigma practitioner with a collaborative style specializing in establishing strategic direction, achievement of business goals and objectives, organizational development and team building, operational efficiency improvement, process optimization, capacity management, inventory control, S&OP, and quality assurance. Experienced with union contract negotiations, plant rationalizations, and cost reduction approaches.



WORK EXPERIENCE

LMI PACKAGING SOLUTIONS
Pleasant Prairie, Wisconsin
February 2010 - Present
VICE PRESIDENT OF OPERATIONS
- Reporting to the CEO as a member of the company?s executive committee, lead all manufacturing, quality assurance, distribution, and supplier partnership activities


ALCAN PACKAGING
Glass Tubing Americas Business Unit, Millville, New Jersey
October 2007 ? September 2009
DIRECTOR OF OPERATIONS
- Reporting to the Vice President/General Manager, directed, managed, and coordinated all aspects of operations for six pharmaceutical glass tubing, vials, and ampoules manufacturing facilities comprising of Tube Draw and five converting sites located in New Jersey, Indiana, Virginia, Nebraska, and Toronto totaling $90+M in sales and 800+ associates. The Unit is ISO 9001, ISO 14001, and OHSAS 18001 certified.
- Sponsored 40+ projects focusing on yield, productivity, and manufacturing excellence basics as the Unit?s Continuous Improvement Champion, resulting in certifications of 1 Master Black Belt, 2 Black Belts, and 15+ Green Belts with annual EBITDA savings in excess of $1.5M for two successive years
- Translated successful EHS best practices between facilities to realize a recordable case rate of 1.04 and a lost-time incident rate of 0.42. Three facilities set records for number of days without a recordable and four facilities set records of number of days without a lost-time incident.
- Devised solutions, justifications, and gained capital expenditure approvals in excess of $10M annually (11% of sales) for the installation of state-of-the-art automation and inspection technology to reduce labor and improve quality levels
- Changed the business model and our profile in the competitive space by virtue of improved technology to provide next generation, value-added products at 10 times sales premium
- Utilized the Sales and Operations Planning (S&OP) process to balance production output with significant demand reductions through 2008 and early 2009. Idled capacity, transitioned products to high efficiency work centers, reduced shifts and headcount, and implemented extended shut down periods.
- Rationalized the business' footprint by analyzing, selecting, gaining approval for, and executing closure of the Nebraska vial converting facility
- Developed and implemented integrated annual operations and strategic business plans to achieve and sustain desired goals
- Filled gaps in leadership and decision making to maintain continuity during the departure and eventual recruitment of the Directors of Sales and Marketing, Quality, and EHS


ALCAN PACKAGING
Tube Draw Operations, Millville, New Jersey
August 2006 ? October 2007
PLANT MANAGER
- Reporting to the Vice President/General Manager, lead and directed a 250,000 sq ft pharmaceutical glass tube drawing facility producing borosilicate, soda lime, and frit products with annual sales of $35M and 145 associates with accountability over mix and melt, forming, engineering, human resources, quality, environmental, health, and safety (EHS), maintenance, material control, continuous improvement, and influence over sales. The facility is ISO 9001, ISO 14001, and OHSAS 18001 certified.
- Winner of the 2008 Global Pharmaceutical Packaging People Award of Vigilance under the category of EHS First
- Winner of the 2007 Shining Star Award from the City of Millville for the facility?s community efforts related to environmental stewardship
- Nominated for the 2007 Alcan Packaging Five Stars Award in the categories of Manufacturing Excellence and People Advantage for leading the facility through a ?Focus Plant? turnaround and driving cultural change for EHS excellence
- Marked improvement was attained in the following business performance metrics:
+ Reduction in recordable case rate of 72% to 1.9, including all-time records for number of days without a recordable and number of days without a lost-time incident, by institution of behavior-based safety practices and safety champion concepts
+ Increase in business gross profit of 46% to $7.8M by implementation of productivity improvement projects and strategic allocation of capital expenditure
+ Reduction in the number of customer complaints by 16%, bringing back customer confidence to increase sales by 15%
+ Continuous improvement EBITDA savings of $1.2M for 2007


WOLVERINE TUBE, INC.
Monterrey, Mexico Operations
October 2004 ? August 2006
PLANT MANAGER
- Started up the company?s maquiladora expansion into Mexico, including establishment of the organizational structure, site infrastructure development, hiring, training, and installation of local teams of management and manufacturing associates, establishment and monitoring of project timelines by assignment of responsibilities and coordination of key project elements
- Managed and directed all plant operations for a 130,000 sq ft facility including two manufacturing departments, human resources, engineering, maintenance, quality, material control, accounting/finance, and import/export totaling 300+ employees and sales of $10.5M and approximately $40M within the first and second years of operations, respectively
- Achieved profitability within four months of startup by meeting the targeted levels of production, operating efficiency, productivity rates, cost, quality measures, safety, yield, on-time delivery, inventory levels, and employee turnover
- Attained ISO 9001:2000 and AD2000-Merkblatt W0 Pressure Equipment Directive (PED) certifications within 5 months of startup
- Developed annual business plans and met monthly financial budgets, including monthly and quarterly forecasting
- Created capital improvement plans, controlled expenses, and approved all major purchases of equipment and supplies
- Represented the company in the community and promoted the company?s goodwill and interest in community activities


WOLVERINE TUBE, INC.
Carrollton, Texas Operations
October 2003 ? September 2004
OPERATIONS MANAGER
- Reporting to the General Manager, managed and directed the total scope of operations for a 168,000 sq ft manufacturing facility comprising of 340+ associates with accountability ranging from two manufacturing product lines, shipping, receiving, and influence over scheduling. Continued tandem responsibility as both Operations and Quality Manager for nine months. Planned strategic direction and continually reviewed key performance indicators. Recognized for consistent success in developing the systems, processes, and procedures to streamline plant operations, revenue, and enhancing profit performance.
- Key contributor in expanding plant sales from $24.4M to $42M and operating income from negative profitability to $5M in a period of 3 years. The facility was recognized as the company?s Plant of the Year during two successive years.
- Achieved changes in the following business performance metrics:
+ Reduction in OSHA incident rate of 47% to 1.66 by focusing on safety awareness and initiating a safety committee
+ Productivity improvement in key product line of 27% by targeted efficiency improvement on low margin products
+ Improvement in delivery performance of 27% to 95+% on time by increasing first pass yield to reduce lead times
- Responsible for meeting monthly financial budgets, including monthly and quarterly forecasting


WOLVERINE TUBE, INC.
Carrollton, Texas Operations
July 2001 ? October 2003
QUALITY MANAGER
- Reporting to the General Manager, oversaw the quality engineering, quality laboratory, and quality control functions of the organization. Compiled and wrote documented quality procedures, including quality manual, training manual, work instructions, control plans, and other quality related procedures to ensure the manufacture of quality products. Formulated and coordinated quality plans, implemented inspection and audit activity, evaluated results, and initiated corrective action when required.
- Administered the ISO 9001 quality system by keeping the system functional and acting as the facility management and quality representative
- Achieved drastic changes in the following business performance metrics:
+ Reduction in external quality DPPM of 61% to 785 DPPM by instituting a "protect the customer" concept
+ Reduction in internal quality DPPM of 90% to 499 DPPM by use of error proofing techniques and improved fixture design
+ Reduction in cost of quality of 29% to 2.80% of value added by installing source inspection and evolving quality inspectors into auditors


WOLVERINE TUBE, INC.
Decatur, Alabama Operations
November 2000 ? June 2001
ASSOCIATE QUALITY MANAGER


WOLVERINE TUBE, INC.
Decatur, Alabama Operations
February 2000 ? November 2000
"WAR ON WASTE (WOW)? PROJECT SUPERVISOR


WOLVERINE TUBE, INC.
Decatur, Alabama Operations
August 1998 ? January 2000
METALLURGIST II


WOLVERINE TUBE, INC.
Ardmore, Tennessee Operations
June 1997 ? July 1998
ENGINEER


WOLVERINE TUBE, INC.
Ardmore, Tennessee Operations
May 1995 ? June 1997
ASSISTANT ENGINEER / COOPERATIVE EDUCATION STUDENT



EDUCATION

Nova Southeastern University, Fort Lauderdale, FL
The Wayne Huizenga Graduate School of Business and Entrepreneurship
MASTER OF BUSINESS ADMINISTRATION
April 1998 ? October 1999
GPA: 4.0/4.0

The University of Alabama in Huntsville, Huntsville, AL
BACHELOR OF SCIENCE IN ENGINEERING
Major: Mechanical Engineering Minor: Mathematics
September 1992 ? May 1997
Cum Laude, GPA: 3.63/4.0



CERTIFICATIONS

Certified Quality Manager, American Society for Quality, March 2001
Certified Quality Engineer, American Society for Quality, December 1999



CONTINUING EDUCATION

"Alcan Corporate Management Development Program", Chicago, IL, Jul 2008
"Alcan Corporate Leadership Program", Toronto, ON, May 2007
?EHS First Site Leadership Workshop?, Philadelphia, PA, Apr 2007
?Six Sigma Yellow Belt Training?, Vineland, NJ, Nov 2006
?Lean Manufacturing Champion Training?, STA Consulting Group, Dallas, TX, Oct 2005 and Huntsville, AL, Jun 2006
?Business and Conversational Spanish?, Berlitz Languages, Inc., Carrollton, TX, Jan 2003 ? Mar 2004
?Six Sigma Awareness and Greenbelt Training?, Elliot Tool Technologies, Decatur, AL, Jun 2003
"Leadership is a Choice: The Four Roles of a Leader", Dr. Stephen Covey, Birmingham, AL, Jan 2001
?Visual Factory Management?, Saddle Island Institute, Huntsville, AL, Mar 2000
?Statistical Engineering for Engineers and Engineering Managers: Problem Solving Strategies?, Shainin LLC, Fairfax, VA, Jun 1999
?Center for Positive Management Leadership?, Atlanta, GA, Sep 1998



MEMBERSHIPS

Institute of Packaging Professionals, 2008
American Society for Quality, 1997



HONORS AND ACTIVITIES

Tau Beta Pi Engineering Honor Society, President, 1995 ? 1997
Pi Tau Sigma Honorary Fraternity, 1994
Alpha Lambda Delta Honor Society, Treasurer, 1993
Dean?s List, School of Graduate Studies, 1998 ? 1999
Dean?s List, College of Engineering, 1993 ? 1997
UAH Presidential Scholarship, UAH Honors Program, UAH Honor Scholar, 1993 ? 1997



LANGUAGES

English - Fluent
Spanish - Intermediate
Urdu/Hindi - Fluent



WORK STATUS

US Permanent Resident; authorized to work in the US for any employer

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VP/Director of Operations/Manufacturing, GM

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