Director of Operations/Plant Manager: Consumer/Industrial Products
Dynamic, lean, hands on operations leader with strong portfolio of P & L successes achieved by implementing progressive and creative changes in processes, people, and materials, generating cost savings in excess of 1.5 million dollars.
* 20 years of Plant Manager experience manufacturing consumer/industrial products in both union and non-union facilities.
* P & L responsibilities for $10-$30 million/year operations.
* Expertise implementing Lean Manufacturing and Quality Management (ISO) sys.
* Conceiving and implementing Strategic Plans with detailed assignments.
* Elevating Individual and team performance through development, assignment, coaching and measuring.
Lean Manufacturing • Analytical Problem Solver • Budgeting & Accounting • Strategic Planner • Excellent Written/Oral Communicator • OSHA Compliance • Excel - Access – Word • ISO 9002 • Contract Negotiation • Project Management
PROFESSIONAL EXPERIENCE
GEA PHE Systems NA, York, Pennsylvania 2008 - 2009
Director of Operations
GEA PHE Sys., a manufacturer of plated heat exchangers, tasked me to build the operations culture of their brand new 200,000 sq. foot production facility; negotiate an operations friendly, initial contract with the UAW; quickly grow the operational capacity of their state of the art equipment to meet projected rapid sales demand; reduce order fulfillment lead times; and substantially improve on time delivery performance.
* Working in close cooperation with Procurement, IT and Sales, implemented new procedures and planning resulting in a reduction in order fulfillment time from 16 weeks down to 4.
* Working in close cooperation with Procurement, Logistics and my own Operations team, on time delivery performance was increased from 60% to 85% within 6 months.
* Negotiated a full labor flexibility contract including unrestricted cross department transfers, merit increases and layoffs by skill level before seniority.
NVF Company, Yorklyn, Delaware 2000 – 2005 and rehired in 2007
Director of Operations
NVF Co., a vertically integrated paper based products manufacturer, charged me to expand their operation and revitalize a stagnant ISO 9000 registration effort. Sales declines eventually led to directing repeated facility downsizing and negotiating for labor flexibility. After an extended Chapter 11 shutdown, I was rehired to assist in a facility resurrection with new products.
* Assumed responsibility and led the process documentation and formalization achieving initial ISO 9000 registration with attendant operational improvements in process and inventory control.
* Negotiated critical survival issue, union concessions on Departmental and multiple Union Local crossing, labor flexible job assignments.
* Automated, established min-max levels and gained inventory and financial control over a several thousand item, $500,000 spare parts inventory, saving thousands of dollars in annual purchasing.
* Conceived and programmed Access based, real time inventory management and costing programs for two product lines, providing critical information for Customer Service, Operations and Accounting.
Federal Mogul Corp., Boyertown, Pa 2005 - 2006
Operations and Engineering Mgr.
Functioned as head of plant manufacturing and engineering for this mass producer of automotive headlights and charged with lowering costs via the expansion of Lean Manufacturing concepts.
* Reduced operational overhead by $80,000 annually by re-engineering two product lines, achieving multiple product line mfg. flexibility with reduced cycle times and eliminating the need for a third shift.
* Brought energy and new focus to plateaued continuous improvement efforts, garnering an overall 5 point increase in plant efficiency from 72 to 77% Overall Equipment Effectiveness (OEE).
* Directed a 40% plant downsizing and still attained all budgeted, operational performance objectives.
Moyer & Son, Souderton, Pa 1997 – 2000
General Manager
In this family owned, regional company, I reported directly to the Partner responsible for their Pet Bird and Small Animal Foods Operations. I was charged to bring structure to the newly created position of General Manager, eliminate the disconnect between Manufacturing and Sales/Marketing, and grow the business.
* Forcefully drove the creation and associated detail accountability of the Division’s and Company’s first 3 year, multi-faceted Strategic Plan. The successful implementation resulted in modernized packaging, focused national advertising, targeted market growth acquisitions and negotiated agreements with similar regional players in California, Montana, and Oklahoma to join in a nationwide consortium.
* Reduced Pet Food packaging cycle time by 20% by re-engineering process to direct flow by eliminating non-value adding conveyor transportation time and negating the need for a planned, status quo Capital Expenditure of $50,000.
Davey Company, Downingtown, Pa 1991 – 1997
Division Manager
In this privately held, three paperboard manufacturing mills company, I was the first Plant Manager to function without a Managing Partner onsite. Tasked with turning around their smallest facility from a breakeven position so as to avoid its potential closure, a restructured team and I “recreated” each department and within two years made it the Company’s leading profit producer, yielding a 10% return before taxes.
Career Note: Additional manufacturing experience obtained with L-3 Communications (Consultant – 1 yr.); Smurfit-Stone Corp.(Mgr. of Mfg.- 6 yrs.); Sonoco Products Co.(Plant Mgr. - 3 yrs.); and GAF Corp.(Industrial Eng. to Ass’t Plant Mgr. – 8 yrs.).
EDUCATION
Master of Science in Management - Rensselaer Polytechnic Institute, Troy, NY
Bachelor of Science in Math - Rensselaer Polytechnic Institute, Troy, NY |
