J erry Sikula

214-***-****

abj65q@r.postjobfree.com

www.linkedin.com/in/jerrysikula/

LEAN MANUFACTURING / OPERATIONS MANAGEMENT

Exemplary record providing the vision and decisive leadership in operations,

manufacturing, quality improvement and project management. Successful at building

plant infrastructures and establishing operating controls that facilitate smooth operations

during periods of significant growth and rapid downsizing. Extremely effective at

integrating emerging technologies and operational systems/processes to solve complex

business problems. Talent for developing high-performance teams, making effective

decisions under any conditions, and quickly revising tactics to achieve goals within

aggressive time frames. Experienced in all phases of lean manufacturing, strategic

planning, program management and problem solving.

CORE PROFICIENCIES:

•

• Lean Manufacturing Management Supplier & Customer Negotiations

• Production and Process Management P&L Management

• Budgeting/Forecasting & Cost Controls

Master’s Certificate Lean Six Sigma

Organizational Development

• Project Management

Strategic/Operational Planning &

• Capital Investments/Projects

Tactical Execution

• Plant Layout/Space Optimization

Re-engineering Business Systems &

• Logistics/ Supply Chain Management

Processes

• Product Planning, Development &

5-S/ DMAIC/ TPM/ SMED

Introduction

Safety/Regulatory/SQF/BRC/AIB

• Value Stream Mapping

PROFESSIONAL EXPERIENCE

Sucden Americas Corp.

9/2013-9/2014

Asset Project Manager (Contract) (Sugar, dry bulk, packaging, liquid)

Reporting to the CEO for North America, responsible for supervising and analyzing all

technical and logistical aspects of potential investments in accordance with a growth

focused business plan. Develop and execute capital projects to improve efficiency and

competitiveness to enhance JIT distribution in the US. Assess companies/technologies

for acquisition from an operational, technical, engineering and performance based

matrix. Responsibilities span all phases of the project execution cycle including

gathering requirements, preliminary design, cost estimation, project evaluation and

justification, equipment procurement, layout, design, construction management and

commissioning. Meet with executive management and board members to conduct

presentations on operational strategies and enhancement projects. Recognized for

ability to identify, design and deploy innovative technologies that result in improved

systems, increased production and decreased expenses.

Selected Contributions:

Appointed by the Board to oversee operation and turnaround of new acquisition

Demonstrated strong problem-solving skills and keen attention to detail, crucial in

managing high-priority, high-visibility, and deadline-driven projects without

compromising quality

Improved quality and efficiency while reducing waste by 7% in 3 months

Hilex Poly Co. LLC 5/ 2012 – 6/2013

Regional Plant Manager (plastics, extrusion, high speed

packaging)

Reporting to the COO, managed and directed the total scope of operations for two

150,000 sq. ft. manufacturing facilities comprising of 150+ exempt and non-exempt

associates with accountability for all manufacturing operations, including financial,

distribution, production, safety, and quality performance operating 24/7 in a high speed,

high volume production environment (HDPE extrusion and converting). Planned

strategic direction and continually reviewed key performance indicators. Responsible

for operational and capital expenditure budgets exceeding $50MM.

Selected Contributions:

Change Agent: Transformed a struggling business unit by using Kaizen principles

that slashed OT costs by 75%, boosted on-time delivery from 75% to 97%,

increased productivity OEE by 11% and improved machine uptime from 70% to

90% while reducing scrap by 5% and customer complaints to the lowest in the

company – all within 1 year

Utilized the Sales and Operations Planning (S&OP) process to balance

production output with significant demand reductions through Q1 and Q2 of

2013. Idled capacity, transitioned products to high efficiency work centers,

reduced headcount, and implemented cross-functional training of hourly

associates during down periods.

Consistent daily production, below budget costs for 2013 YTD, optimizing the

bottom line

Demonstrated lean manufacturing background and a proven ability to drive

process improvements – implementation of standard work, 5S and visual

management

American Sugar Refining, Inc. (Domino Sugar, C&H, Florida Crystals) 1995 – 2012

Plant Manager - Dallas, TX (Dallas facility closed in

6/2012)

Promoted to hold full responsibility for production, quality, safety, and cost structure for

this new facility acquisition to the company in 2007. Establish operational policies and

implement process improvements to ensure superior quality and outstanding output for

high-speed packaging equipment in the production of sugar, sweeteners, creamer, salt

and pepper. Directly manage six supervisors/managers overseeing 70+ exempt and

non-exempt employees in a 24/5 operation. Design and implement coaching and

training programs to develop staff, facilitate efficiency, and improve performance.

Manage operational and capital expense budgets exceeding $17M. Ensure adherence

to strict quality control procedures which resulted in Superior Quality ratings from AIB,

Silliker and SQF.

Selected Contributions:

Implemented and directed lean manufacturing initiative for reducing waste and

production over-runs saving over $200K annually.

First facility in the entire company to become SQF (Safe Quality Food) Certified

in 2011

Five years without a Lost-Time-Accident (LTA)/ OSHA DART Rate = 0.00

Increased Efficiency by 10% and reduced line waste by 15% through employee

training

Integrated Project Management ($2M) of Production lines and Infrastructure

upgrades two months ahead of schedule and 5% under budget

Operations Manager – Chicago, IL

Liquid Process Station, Bulk Delivery, Warehouse/Transfer Station

Responsible for planning production operations for liquid process and production of

sucrose and inverts; establish priorities and sequences for manufacturing process.

Direct involvement in Project Management and Capital Expenditures including vendor

procurement. Accountable for all production, quality, safety, maintenance and

scheduling of production. Completed analysis of production and operating reports that

resulted in resolved operational, manufacturing, and maintenance problems to ensure

minimum costs and prevent operational delays. Cost accountability within the $10M

operational budget processing over 100M pounds of sugar annually. Train, coach and

evaluate employees. Coordinate liquid syrup production, barge/rail unloading and bulk

transfer loading.

Selected Contributions:

Improved Quality Standards which resulted in first AIB Superior Rating

Process improvements that reduced waste stream saving over $100K annually

Reduced overtime by 15% by implementing process improvements

Liquid Plant Manager/Manager of Shipping and Receiving - Cleveland, OH

Developed production schedule for liquid melt operation, packaging of drums, pails and

totes of sugars and corn syrups and rail unloading for a 2 shift operation. Provided

leadership and support, initiating, monitoring, assisting, and improving all aspects of key

metrics: safety, quality, productivity, delivery, cost, and continuous improvement.

Designed improved loading and unloading procedures and trained staff to minimize

product damage and loss. Established and maintained effective business relationships

with freight carriers, improving on-time deliveries and unloading time.

Selected Contributions:

Played integral role in start-up of new product line into existing operations

Reduced overtime by 25% by implementing procedure and process

improvements

Improve on time performance of deliveries by 30%

EDUCATION/TRAINING

MBA – Master of Business Administration -2015 (expected)

West Texas A&M University

Master’s Certificate – Lean Six Sigma Black Belt -3/2014

Certificates: Green Belt (9/2013), Lean Six Sigma (11/2013), Black Belt (03/2014)

Villanova University

Bachelor of Science - Aerospace Management Technology - Minor in Business- 1992

Kent State University – Kent, Ohio

Cane Sugar Refiner’s Institute 2011

Nicholls State University

Thibodaux, Louisiana

References Available Upon Mutual Interest

Contact this candidate