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Summary
This Fractional Plastics Manufacturing Executive is a highly accomplished Plastics Manufacturing Operations Leader. Armed with a Bachelor of Science degree from the University of Minnesota: Mechanical Engineering; and youthful experience in the plastics manufacturing, he was recruited into well-regarded companies including, Anchor-Hocking and Newell/Rubbermaid Corporation. He excelled there and then ventured into multi-faceted plastic companies, with varied technologies and markets.
This Fractional Plastics Manufacturing Executive’s ability to develop and implement lean principles, process improvements, and to facilitate operational and organizational change has led to significant profit improvement; often exceeding company expectations and goals. His strong analytical and problem-solving abilities has enabled Doug to identify troublesome issues, create a plan, and quickly resolve the challenge with a successful solution.
His project management skills and financial acumen have delivered consistent on-time and cost-effective solutions to complex programs. Working with acquired teams, Doug has fostered productive group dynamics; motivating and mentoring employees to achieve corporate and individual goals.
Highlights
- P&L Management / Strategic Planning
- Revenue & Profitability Growth
- Process & Productivity Improvement
- Lean Manufacturing and Continuous Improvement- Green belt Certified
- Large Client Relationship Management
- Proficient in ISO 9001-2015/IATF 16949
- Risk management and Key Performance Indicators- KPI
- Vendor Management
- Plant Manager Experience
- Capital & Operating Budgets
- Production Management & Scheduling
- JIT Just-in-Time manufacturing
Plastic Process Experience
- Injection Molding- Commanding knowledge of injection molding, tooling design and development, machine and support equipment, secondary processes, resin selection, facility design, and assembly processes.
- Blow Molding – Proficient in extrusion and continuous extrusion blow molding and secondary processes for trimming and assembly of consumer and industrial parts.
- Extrusion Molding – High aptitude and experience in profile and sheet extrusion processes and secondary processes for the manufacturing of electrical wire and heavy gauge sheets for thermoforming.
- Thermoforming – Highly skilled in materials, part design considerations, tooling, trimming and checking fixtures, and secondary processes for the thermoforming of production products using heavy gauge thermoforming. Applications include heavy truck, agricutural equipment, high speed rail, medical equipment housings, funeral service products, and consumer products.
- Resin Selection & Material Science – Knowledgable in engineering resins, commodity plastics, and elastomers.
- Process Automation & Robotics Integration – Implemented automation strategies to enhance production efficiency and reduce labor costs resulting in significant EBITA gains.
Relevant Accomplishments
- Implemented Lean Manufacturing, Kaizen Procedures and Continuous Improvement Programs. Assembled a cross-functional cost reduction team that identified and streamlined poor performing processes and products; average savings $20,000 per month.
- Efficiency Achievements.
- Reduced overall plant scrap rate by 50%; resulting in a $2MM cost savings.
- Reduced key product scrap by 30%; tooling redesign and process improvements.
- Directed, trained and mentored engineering, maintenance, and tooling staff; offered engineering expertise to customers; resulting in 200+ new profitable projects/yr. and $5MM of additional new sales in one year.
- Converted a warehouse into a manufacturing facility; designed plant layout, manufacturing cells and work flow; resulting in an additional revenue of $2MM per year.
- Implemented new assembly processes and work cell layouts on a newly integrated product line improving efficiencies by +40%.
- Directed Product Development and Launch; Fiscal budgets, Capital Acquisition, Compliance. Coordinated a project management process based on APQP principles to expedite product launch; reducing project timelines by 25%. Operational budget and profit and loss analysis; resulting in over $40,000,000 in capital acquisitions. ISO 9001-2015 compliance and achieved 100% environmental, health and safety compliance.
- Coordinated “Ramp-up” and Facility Expansion. Hired and trained 50 assembly personnel in a 60-day period to support required production ramp up. Developed and instituted quality standards and standard work procedures to ensure quality and on-time delivery on newly integrated product lines.
- Optimized Productivity, Best Practice and Drove Technology Expansion. Implemented Lean Manufacturing Principles, 5S, visual management, value stream mapping and continuous improvement and applied technology; resulting in savings exceeding business goals and objectives and commendations from customers for outstanding performance. Employed new technologies; robotics, automated work cells and in-mold labeling. Collaborated with a major customer and a vendor to reduce costs for the customer; resulted in a new opportunity which garnered an additional $500K in revenue.
- Customer Support to Sales Growth. Fostered clear, open and honest communication and contract negotiations with company team members, vendors and customers; resulting in mutual understanding and satisfaction.
- Led a Distressed Plant Operations. Directed a plant turnaround. Positioned a portion of the blow molding plant for sale and then restructured remaining operations for financial success. 80 employees, $12MM in Sales, $6MM operational budget.
Roles
- Thermoforming Engineering Manager, Wilbert Plastic Services
- Director of Engineering/ Director of Assembly/Engineering Manager, Plastech Corporation
- Plant Manager/Engineering Manager, Emplast
Request Expert / Similar Expert
Click “request expert” for a free initial screening call with this expert or a similar expert regarding your expert consulting needs
To apply for this job email your details to haleymmagnani@gmail.com
