Interim Plant Manager – Discrete Manufacturing

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Summary

This interim plant manager is a process-driven leader with global experience in driving process growth and improvement. Through effective use of a combination of Six Sigma, Lean and metric-driven actions, he has effectively led the transformation of manufacturing operations, in multiple industries across multiple cultures. Through effective engagement of teams at all levels and across multiple disciplines, he has improved throughput and reduced cost, while improving quality and employee engagement.

Highlights

• 30+ years of experience
• Participated as Lean Six Sigma Green Belt on improvement projects
• ISO/TS/QS/AS systems implementations
• Global manufacturing and supply chain leader

Relevant Accomplishments

• Launched first Just-In-Time manufacturing facility starting with a ‘clean sheet” completed the acquisition of the facility, equipment purchases and installation, employee hiring and training, as well as customer approvals for effective launch.
• Led QS900 implementation at new plant in Ontario Canada and subsequent Q1 certification
• Led launch of production for new complete seat programs as a tier 1 supplier
• Led lean implementation of assembly process in a casino sign business which doubled daily output without adding labor. Replaced cell build with balanced production line process and drastically improved quality.
• Led launch and operations of 4 new facilities from green field to full production.
• Reduced overall inventory by 40% globally through effective scheduling techniques and process flow improvements
• Reduced warranty costs by more than 40% to less than 1% of revenue, while improving delivery times to dealers, through lean scheduling and KPI monitoring.
• While leading the operations team, implemented several equipment tracking processes which led to dramatic increases in up-time for critical process equipment. This included the plasma cutting equipment which was running at less than 25% utilization to more than 50% cutting utilization, through maintenance and scheduling processes, and monitoring PLC data to drive results. This was done using core concepts of the Toyota Total Productive Maintenance Process.
• Through effective scheduling and monitoring, reduced from three shifts to two shifts and maintained same product throughput, without added manpower.
• Effectively reduced lead times to dealers through schedule posting and product tracking to assure that product was moving in a timely fashion. This involved implementing a bar code scan process that identified when customer orders were taken, started, completed and shipped. Through holding each area accountable to process complete orders in a timely basis, we were able to reduce order to customer lead times by more than 50%, providing a competitive advantage.
• Developed effective reports from the homegrown ERP system which allowed supply chain buyers to reasonably forecast and procure materials on a timely basis. I developed and trained new purchasing professionals at both manufacturing locations to assure proper implementation.

Roles

• Foundry operations
  • Production Supervisor
  • Assembly production supervisor
  • Master scheduler
  • Purchasing agent
  • Manager production and inventory control
• Automotive Group
  • Materiels manager
  • Assistnat plant manager
  • Group supply chain manager
  • Operations manager assembly
  • Launch manager manufacturing operations
  • Plant manager- automotive assembly complete seats
  • Launch manager- complete automotive interiors
  • Director of operations- multiple site seat assembly operations.
  • General manager operations- European Interiors group
• Climate Controls Solutions Group
  • Vice President Global Operations
• Residential Heating and Air Conditioning Division
  • Director of operations
• Trailer Corporation
  • Interim General Manager
  • Interim General Manager
  • Consolidation launch manager
  • Vice President Operations
  • Chief Operating Officer

Education/Certifications

• Bachelor of Science degree
  • Major Marketing and Management

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