John F. Long

**** ******* ***** **** ab8cxf@r.postjobfree.com

Home: 615-***-****

Christiana TN 37037 Mobile:

615-***-****

Professional Experience:

ATI Tungsten Materials, 2009 -

Present

LaVergne, TN

Director of Engineering/Maintenance/Continuous Improvement

Reports to the ATI Tungsten Materials President, Primary role: Manage all

Engineering/Maintenance and Continuous Improvement.

Facility Accomplishments:

> Develop working roles for all corporate engineering and maintenance

managers.

> Develop Continuous Improvement and Lean Manufacturing program,

> Develop/Implement maintenance systems and financial systems for all

engineering.

> Develop and managed project management systems for all capital

projects.

> Administer cost savings projects though out all business units

> Develop working role for maintenance

> Establish production tracking system

> Manage two machines shops, tool repair and tool design. (one Nashville

one in Alabama)

> Implementation of OEE World Wide

Financial Accomplishments:

> Implementation of Maintenance Repair and Operation programs for

maintenance cost savings $360,000 first year.

> Implementation of Lean and Continuous Improvement (MU and CU) cost

savings $300,000 first year.

> Reduced engineering cost from $102,000 to $56,000 a month

> Manager all capital request from $10,000 to $100,000,000

> Reduce maintenance work force (Manning & MRO) from $3,000,000.00 down

to $1,200,000.00

Johnson Controls., 1990 - 2008

Cadiz, KY

Plant Manager (Focused Factory)

Reported to the VP of Operations, Primary role was to manage all

Operations/Engineering, along with the shut down and relocation of all

production equipment though out Johnson Controls. Manage plant

engineering, continuous improvement and a maintenance support staff during

a 3-shift 7-day operation.

Facility Accomplishments:

> Managed the launched of two Major Customer's programs, Honda &

Toyota, back to back. Honda required the installation of 11 weld

cells, two stamping presses & four quad cells, Toyota installed

eight weld cells & one stamping presses.

> Developed and planned Project for budget usage and running cost: Honda

$1.2 m, Toyota $900,000

> Developed working role for 4 program managers, 2 tool engineers and 3

ME's

> Manage two plants on layout and material flow.

> Coordinated work force, using millwrights and electrical contracts for

equipment install to meet all safety guidelines for all facilities.

> Coordinate all vendor build, to maintain a strong communication for

equipment standards.

> Set labor standards for production and floor operations

> Coordinate working role for all Maintenance, Tooling and Controls

Engineers for the new equipment install and day-to-day programs.

> Managed electrical and mechanical work though the use of outside

contractors as well as in-house technical support during the

installation phase.

> Sign off on all tooling prints and machines layout during program

launch.

> Attend all run at rates to assure customer tack time, and final

equipment sign off.

> Manage set-up all maintenance and engineering systems though tool crib

manager and plant engineer.

Financial Accomplishments

> Exceeded Plant Improvement Profit Plan Savings Goals for: FY' 06 (by

$1.5), FY' 07 (by $750 k), and FY' 08 (by $892 k).

> Implemented Lean Manufacturing systems,

> Develop a Material Replenishment System to improve machine utilization

plant wide by 15%.

> Manager labor cost from $13,000 a day down to $4,000 a day

> Manager purchase burden from $900,000 a month down to $700,000 a month

> Reduce labor force by 30% in 7 months

> Manage a plant income from a negative $100,000 a month loss to a

positive income of $250,000 a month.

San Antonio, TX

Site Technical Manager/Launch/Continuous Improvement reported

Reported to VP of Operations, Primary role, build two plants, one 500,000

square feet facility and one 200,000 square feet facility. Layout with two

Engineering Managers both plants for electrical, air, water and hydraulic.

Coordinate the equipment purchase with program managers. Manage two plants:

one process center, (injection molding, assembly, welding, over head

systems and foam) and one Just In Time plant (seat assembly, over head

assembly), engineering and a maintenance support staff during a 3-shift 7-

day operation.

Facility Accomplishments:

> Program Manager for a complete build, assemble and start up of both

plants, ($65,000,000) project

> Set-up and manage all maintenance and engineering systems

> Launch in two plants in 7 month: "one" Just In Time Seat, Headliner

and Shipping Systems and "one" Process Center with 2 Foam Lines, 3

Injection Molding machines including a 700 ton, 1500 ton and the first

3000 ton (first in the states),

> Operating 11 weld cells with three stamping presses including a 1000-

ton, 2500 ton and 4000 ton, one headliner press and 11-door assembly

work cells.

> Set labor standard for production and floor operations

> Managed a plant program manager, two-maintenance manager, two

engineering manager, and two continuous improvement managers on a day-

to-day bases as well as during a $65,000,000 launch.

Financial Accomplishments:

> Implemented Lean Visual Management

> Design and implement Material Replenishment Systems to improve machine

utilization for both facilities.

> Manager labor cost to accommodate fluctuation of customer volumes

> Manage purchase burden of $4,000,000 per year

> Reduce labor force by 30% in 7 months

> Manage the plant income from a $100,000 a month loss to a positive

income of $150,000 a month

Missouri

Site Technical/Project Manager

Reported to the Director of Operations, Primary role to build and assemble

the DC plant (distribution plant) and manage all Engineering activities in

two plants (battery assembly and batch and fill operation). Manage two-

plants engineering and a maintenance support staff during a 3-shift 7-day

operation

Significant Accomplishments:

> Set-up and manage all maintenance and engineering systems

> Oversee the build of a DC plant with two Program Mangers, 2 Industrial

Engineers and the maintenance work force. Total Project $110,000,000

> Over see the installs of over 20000 linear feet of conveyor along with

automated picking system.

> Over see the complete build and install of a new battery assembly

system. (New to Johnson Controls)

> Program Manage the design and install of the Mark 7-B battery machine

to increased productivity by 30% and reduce labor 10% ($10,000,000)

project

> Manage both facilities with two Engineering Managers, 2 CI managers

and 2 IT managers.

> Implementation Lean Visual Management

> Manage the plant income for a of $10,000,000 operating budget

> Developed Material Replenishment Systems to improve machine

utilization plant wide

> Build and manage by EQU system

> Manager purchase burden of $15,000 per day

> Reduce labor force by 20% in 1 year

Missouri

Site Technical Manager/Launch/Continuous Improvement

Reported to the Director of Operations, Primary role was to Project manage

the replacement of older equipment. Additional, responsibilities manager

CI department though a CI Manager and four black belts. Manage two-plants

(injection molding and rubber extrusion) engineering and a maintenance

support staff during a 3-shift 7-day operation.

Significant Accomplishments:

> Direct the Implementation of Lean Visual Management systems on all the

production floors.

> Program managed two site builds with 12 machines including injection

molding (ranging from 750 ton to 300-ton presses) and rubber

extrusion. ($65,000,000) project

> Set labor standard for production and floor operations

> Set-up and manage all maintenance and engineering systems

> Programs manage two sites installing 13-injection molding presses

(ranging from 750 ton to 300-ton presses) and 12 rubber extrusion

machines. ($65,000,000) project

> Coordinate all tooling modification though 4 tooling engineers and 12

tool makers

> Manage both facilities though two-plant engineers CI manager, two

maintenance managers.

Regional Engineering Manager/Launch Manager/Continuous Improvement Manager

Reported to the President of Engineering, Primary role, manages all

Engineering Operations activities in the Ford Just in Time business unit.

Additional responsibilities included managing the CI department though a CI

Manager. Manage 12 plant engineers and a maintenance support staff for the

Ford business unit.

Significant Accomplishments:

> Program manage the complete build of the systems (programming, set-up

and production systems)

> Developed Material Replenishment Systems for a 8 hour inventory

systems (material storage systems)

> Design and build a complete plant and shop floor systems (barcode,

shipping and tracking systems)

> Design and manage delivery systems to accommodate customers shipping

requirements.

> Manager purchase burden for 12 plants, $30 million budgeted.

> Set-up and manage all maintenance and engineering systems

> Oversee the build of a 500,000 square foot building, complete with all

needed facilities and assembly system.

> Relocate a complete assembly system in 7 days including all shipping

systems, assembly system, computer systems and shop floor process

> Oversee year model change and install new equipment for 12 Ford and

Assembly plants.

> Support engineering operations for 12 plants though - 12 Engineering

managers, 12 CI Managers, and a corporate staff of three Electrical

Engineers, four Mechanical Engineers and three Industrial Engineers.

> Manager purchase burden for 12 plants of $50,000,000

> Set-up and manage all maintenance and engineering systems

Education:

1982 UNIVERSITY OF TENNESSEE - BSEE

Certified Six-Sigma Green Belt & Black Belt

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