Resume - Plant Manager, Quality Manager, Industrial Engineer

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Resume #78864

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Quality Manager/ Production Superintendent/ Industrial Engineer/ Continuous Improvement

Summary
Hands on professional with 15 years of Quality Management and Industrial Engineering experience, combined with a history as a Plant Manager for a Green Field Start up in the Automotive Industry. Developed and implemented successful Strategic Plans, P & L Budgets, Quality Management Systems and Muda (waste) reduction strategies. Currently a member of a Turn Around Team for a division of the Fortune Brands organization. Expert knowledge of Organizational Behavior and performance, Lean Six Sigma methodology as well as manufacturing and transactional process control and improvement. Additional experience in Design of Experiments (DOE), Statistical Process Control (SPC), Advanced Product Quality Planning (APQP), Failure Mode Effect Analysis (FMEA), Control Plans and Production Part Approval Process (PPAP), with an emphasis on error proofing and root cause (8D) identification and systemic corrective action. Developed a highly acclaimed reputation for attention to detail as well as developing highly effective, interdependent work groups via training and Kaizen events.
Business Experience
Master Brand Cabinets, Las Vegas, NV 2005 to Present
Transition Team Quality/ Industrial Engineering
Led overall Quality paradigm shift in transition facility. Developed Customer Satisfaction Survey, Cost of Quality (COQ) data collection and reporting. Trained department leads and team members in Quality Awareness, Data Collection, Lean Six Sigma, 5S, SOS development and other basic continuous improvement tools. Perform basic and advanced Industrial Engineering functions such as value stream mapping, time studies, workload calculation & balancing, production cell layout & design as well as poke yoke and visual management implementation. Also responsible for investigation, documentation and systemic correction action of non conforming product and any other customer concerns issues.
* Redesigned production line and balanced workload to increase production capability by more than 15% in 2005, another 25% in 2006 and 25% in 2007 at a total three year capital cost of less than $15,000 with no additional labor. Recently completed $3 million plant retooling project that doubled production from 2007 level and increased the market serviced from 2 states to 9.
* Reduced non-conforming product volume and NCP recovery time resulting in increased on time delivery and ship complete to 99.8% up from 45% and 52% respectfully in 2005.
* Using basic and advanced Lean Six Sigma principles I eliminated non value added waste by $515,000 in 2006 and another $422,000 in 2007.
* Facilitated Kiazen team that reduced process time from order placement to product delivery from 32 days to 8.

MetoKote Corporation, Longview, TX 2003 to 2005
Plant Manager
Responsible for start up and operation of a small on site Automotive Tier 1 production facility.
Facilitated development of Vision, Mission, Goals, Objective, Key Result Area, and Metrics with team members. Directly responsible for plant safety, OSHA compliance, and on site waste water treatment operation and compliance to all federal and local Air quality and waste water permits. Budget development and Profit and Loss responsibility/ EBITDA reporting & control for plant with 5 Million dollars in annual sales. Performed all human resource functions such as hiring, training and leading team members in all aspects of operation from Strategic Planning to Standard Work procedure development. Direct liaison with Customer on all issues from Accounts Receivable to product delivery. Personally responsible for Supplier development and certification and Accounts Payable.
* Created production system, proactive process control policy and procedures, preventative action plans, reaction plans and quality system resulting in a parts per million (PPM) defect rate of 0.35.
* Built highly effective interdependent relationships with all levels of customer leadership resulting in high performance working relationship between the two organizations.
* Zero recordable injuries, Found in compliance during all inspections regarding federal and local permits.
MetoKote Corporation, Sumter, SC 2002 to 2003
MetoKote Corporation, Sanford, NC 2000 to 2002
Quality Manager
Directly responsible for generating revenue by ensuring product quality and compliance with customer specifications for more than 200 parts for 40 different customers. Customers vary from automotive, such as Bosch Braking Systems, Volvo, GM & Ford to agricultural giants John Deere and Caterpillar. Direct and manage all aspects of QS-9000 system. Perform APQP, PPAPs, Statistical Process Control (SPC) implementation and evaluation, ensure irreversible Corrective Action is taken to customer issues and perform feasibility analysis for all new parts introduced to the electrodepisition, powder and wet spray coating processes. Direct, develop and supervise human and material resources for industrial pretreatment and coating processes, wastewater treatment facility and quality assurance/ performance testing laboratory (which performs in excess of 2000 test procedures per week including statistical process control). Additional duties included the direction of continuous improvement opportunities via team formation & facilitation as well as 5S and lean manufacturing principle implementation and team member development and responsible for inventory & cost of quality tracking and management.
* Metokote Regional Quality Management Systems Lead Auditor with a specific reference to the Automotive Industry (ISO 9001:1994)
* Served as the primary advisor and coordinator with customers and suppliers for the start up of new projects.
* Direct, develop and supervise human and material resources for industrial pretreatment and coating processes, wastewater treatment facility and quality assurance/ performance testing laboratory (which performs in excess of 2000 test procedures per week including statistical process control).

US Air Force, Seymour Johnson AFB 1991 to 2000
Squadron Quality Advisor
Facilitated development of squadron and department strategic plan, vision, mission, goals, objectives, key result areas, action plans, metrics and their evaluation processes. Facilitate the chartering of process action teams to identify improvement opportunities, analyze current process, collect and analyze data on current process, suggest improvements of processes to process owners, monitor new processes and metrics, and standardize solutions to processes in need of improvement. Member of Hospital Quality Council with the responsibilities of responding to and resolving customer complaints, qualities of care issues and ensure compliance with JAHCO federal standards.
* Facilitated Continuous Improvement Team (Kiazen event) for 4th Fighter Wing resulting in ability to generate air power and put bombs on target anywhere in the world within 36 hours, down from 64.
* Numerous CI team projects involving medical ancillary services (Lab, Radiology, Pharmacy) reducing patient service waiting times, and increasing medical care quality.
Education
Mount Olive College, Mt. Olive, NC 2000
BS, Management and Organizational Development
Skills
* Proficient in all standard MS applications as well as MS Visio, MS Project, Mini Tab, Auto Cad
* Business generalist with record of achievement in applying administrative, business, human resource and marketing skills to effectively manage projects and ongoing operations.
* Comprehensive knowledge and experience in group facilitation and organizational development. Constantly looking for and discovering simpler and more effective & efficient methods of operating.
* Strong communication, motivation, team building, liaison, and leadership skills. Recognized as a role model and mentor for new team members
* Business generalist with record of achievement in applying administrative, business, human resource and marketing skills to effectively manage projects and ongoing operations.
* Earned a reputation as a valuable and cooperative coworker by: being fair, honest, and willing to help others when needed; effectively resolving conflicts at appropriate times; and assisting new managers and other staff to become familiar with policy and operations.

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