RALPH L HENSKI

*** ***** *** - *********, ** ****6

567-***-**** (cell) E-mail: abmsup@r.postjobfree.com

EDUCATION

M.B.A. Business Admin (approx 30% cmp) Ashland University

Ashland, OH

B.S. Business Administration Urbana University

Urbana, OH

A.A.S. Industrial Engineering Mgt Edison State College

Piqua, OH

CERTIFICATIONS

Six Sigma Green Belt

Certified LEAN/DFSS

PROFESSIONAL EXPERIENCE

Medalist Laserfab, Inc, Oshkosh, WI $22M Sales Multi-Plant

Operation 2008 to 2009

Director of Manufacturing Operations

Metal Fabrication-Contract Manufacturing-DoD, Automotive, Railroad

Industries

Successfully managed and directed turn-around situation of a business

experiencing very low on-time delivery and supplier ratings, 100+ direct

labor personnel in three (3) facilities P&L and budgetary responsibility of

plants, directed and managed manufacturing and support functions of

purchasing (2), engineering (4), production scheduling (1), inventory

control (4), shipping and receiving (5).

Accomplishments & Improvements:

*On-Time Delivery from 74 to 98% *Raw Inventory 65% Reduction

*Supplier Rating from 56% to 98%

*Labor Reduction Weld 38% *WIP 10 Days to 2 Day Avg *Productivity

54% to 88% Press Brake

Project Management Accomplishments:

Capital Equipment: (2) Robotic Weld Cells, New fixtures for Weld Cells

Building: New Roof Membrane, Parking Lot Upgrade

Continuous Improvement: 5S, Work Instructions, Preventive Maintenance

Program, OEE Measure, Shop Safety Committee Implementation

Processes/Equipment: Sheet Metal and Structural Metal Fabrication, Laser,

Turret Press, Press Brake, Tube Cutting, Tube Bending, Robotic & Manual

Welding; CNC & Manual Machining

Collins Industries Inc 2003 to 2008

Director of Operations, Mid Bus, Inc, Bluffton, OH $32M Sales

Manufacture of Type A School & Activity and Specialty Buses-

Automotive/Government/Specialty Vehicle

Successfully managed and directed turn-around situation of plant with

negative gross margin, EPA fines and issues, OSHA related issues, with

increasing warranty costs, lack of quality and poor delivery performance.

Responsible for Manufacturing Operations, Engineering,

Materials/Purchasing, HR, Quality, Shipping, Receiving and Stockroom

comprising of 14 salaried/indirect and 150+ hourly in a 3-shift operation,

180,000 sf ft facility. Managed P&L, budget, EPA and OSHA Safety compliance

and reporting for facility.

Accomplishments & Improvements:

*5.2% operating loss to a 10.9% operating profit *Leadtime

reduction 27 days to 11 days

*Reduced percent of labor per unit by 22% *Reduce manufacturing

area from 180K to 120K

*Increased inventory turns from 3 to 17 *Reduced OSHA recordable

injuries from 23 to 2

*Lost days from 25 to 0 *Instituted technology

based plan in Primary

*Reduce warranty costs by 46% in 2005 reducing labor by

+50%

45% in 2006, and 53% in 2007 *IPV(Incidents Per Vehicle)

2004=3.03, *Reduced Hazardous waste streams from 15 to 3 2005=1.80,

2006=.76, 2007=.35

Project Management Accomplishments:

Capital Equipment: Robotic Weld Cell, Semi-Automated Roof Weld Fixture,

Floor Weld Fixture, Body Assembly Fixture, Paint Booth & Oven, Plural

Paint System

Building: New Roof Membrane, Factory Office Renovation, Factory Lighting,

Plant Layout

Continuous Improvement: Lead LEAN implementation, including training staff

and employees in lean tools including 5S+1, kanban, waste identification

and elimination, SMED, VSM and problem solving techniques. Implemented PM

Program, OEE Measures, Reduced Hazardous Waste Streams from 15 to 3

Processes/Equipment: Sheet Metal and Structural Metal Fabrication, Plasma

Cutting, Turret Press, Press Brake, Robotic & Manual Welding; CNC & Manual

Machining; Paint; Wire, Cable & Harness Assembly; Seat/Upholstery;

Assembly

Continue- Collins Industries Inc

Plant Manager, Wheeled Coach, Inc, Hutchinson, KS, $65M Sales

Multi-Building Operation

Manufacture of Custom and Standard Ambulance and Rescue Vehicles-

Automotive/Specialty Vehicle/DOD

Lead a successful turn-around situation for satellite facility with

negative gross margin, severely behind schedule, poor quality with

increased warranty costs. Responsible for leading and directing

Manufacturing Operations, Engineering, Materials/Purchasing, HR, Quality,

Shipping, Receiving and Stockroom comprising of 18 salaried/indirect and

180+ hourly in a 1-shift operation, in a campus setting of seven (7)

different building totaling 240,000 sqft. Managed P&L, budget, PA and OSHA

compliance and reporting for facility.

Accomplishments & Improvements:

*2.9% operating loss to a 8.3% operating profit *Reduced percent

of labor by 26%

*Reduced past due units from 33 to 3 in 6 months *Achieved a 96% on-time

delivery rate

*Leadtime reductions from 35 to 21 days MODs *Leadtime reduction from

21 to 11 days for Vans

*Inventory turns from 6 to 14 *Reduced warranty claims

cost in 2003 by 58% *IVP(Incidents Per Vehicle) 2002=2.91,

and 46% in 2004

2003=1.08, 2004=.47

Project Management Accomplishments:

Capital Equipment: CNC Wood Router, Omal Doweling Machine, CNC Edge

Banding, Lamination Press, Plural Paint System, Fiberglass Molds

Building: Factory Office Renovation, Factory Lighting, Facilities/Plant

Layout

Continuous Improvement: LEAN implementation, including training in lean

tools including 5S+1, kanban, waste identification and elimination, SMED,

VSM and problem solving techniques, PM Program

Processes/Equipment: Sheet Metal and Structural Metal Fabrication, Plasma

Cutting, Turret Press, Press Brake, Manual Welding; CNC & Manual Machining;

Cabinet Making; Paint; Wire, Cable & Harness Assembly; Upholstery; Assembly

PECO II, Inc, Galion, OH $240M Sales 1999 to 2003

Director Advanced Manufacturing/General Manager Support Business Unit

Manufacture of Power and Distribution Equipment for Telecommunications

Industry

Manage and direct with P&L and budgetary responsibility of Support

Business Unit consisting of 350 plus hourly and 30 salaried/indirect

employees in a 480,000 sq ft facility including Manufacturing Operations,

Design Engineering, Manufacturing and Industrial Engineering, Purchasing,

and Material Control within SBU.

Accomplishments & Improvements:

*Exceed Operating Profit 2 of 3 years *Increased Overall Inventory

turns from 3 to 16

*Cabinet Leadtime from 10 days to 3 days *Direct Labor Reduction

Bus Bar Fabrication 58%

*Reduced Internal Fabrication Rejects by 73% *Reduced Raw Fabrication

Inventory 65%

*Reduced WIP 75% in Harness Department *Reduced WIP 83% in

Fabrication

*Reduced WIP 62% in PCB *Setup Reduction Bus Bar

Fabrication 84%

Project Management Accomplishments:

Capital Equipment: EHRT CNC Punch, EHRT CNC Bender, RAS Folding Machining,

Hass VMC, Komax Cable Machine, Eubanks Automatic Wire Processor, CableScan

Harness Boards/Fixtures, Bobbin Winding Equipment, Material Handling

Equipment, Wave Solder System, Aqueous Cleaner, Pad Printer

Building: New 280K sq ft facility, Factory Office Renovation, Factory

Lighting Old Building, Facilities Layout

Continuous Improvement: Training and implementation of LEAN tools

including 5S, kanban, waste identification and elimination, SMED, VSM and

problem solving techniques, OEE measurements

Processes/Equipment: Sheet Metal and Structural Metal Fabrication, Laser,

Press Brake, Welding, Powder Coat; CNC & Manual Machining; Wire, Cable &

Harness Assembly; Transformer and Chock Assembly; PCB; Assembly

Amphenol Interconnect Products Corp, Columbus, OH $5M Sales 1999 to 1999

Plant Manager: Contract Manufacture of Communication and Power Cables and

Wire Harnesses

Successfully lead a start-up satellite manufacturing operation.

Established manufacturing infrastructure; exceeded quality and delivery

goals. Full P&L and budgetary responsibility of plant, directed and

managed Human Resources, manufacturing, purchasing, quality, inventory

control and customer service. Organized, trained and lead the plant on

LEAN.

Processes/Equipment: Wire and Cable (cnc & manual cut, peel, terminate);

Harness Assembly.

Angell Mfg Co, Dayton, OH $12M Sales 1997 to 1999

Plant Manager: Manufacture of Decorative Overlays and Stampings-Automotive

and Appliance Industry

Successfully directed and managed the performance of a union facility in a

turn-around situation. Implemented Lean manufacturing techniques 5S,

kanban, SMED, visual management throughout plant. Managed and conducted

grievance process and member of contract negotiation team.

Project Management Accomplishments:

Capital Equipment: (2) Automatic Stack/Sort Equipment, UV Cure Oven, Semi-

automated Laminator, Clam Shell Press, Emulsion Application Equipment,

Semi-automated Screen Cleaning System

Building: Facilities Layout

Continuous Improvement: Training and implementation of LEAN tools

including 5S, kanban, waste identification and elimination, SMED problem

solving techniques

Processes/Equipment: Semi-automatic and Manual Printing-1st and 2nd

Surface (Solvent & UV Inks); Screen Making; Ink Mixing; Color Matching;

Forming; Laminating; Stamping Presses; Clam Shell Press; Assembly.

Hobart Bros Co, Troy, OH $350M Sales Multi-facility Operations (3)

1989 to 1996

Manufacture of Welding Equipment, Industrial Battery Charges and Airport

Ground Power Equipment-Capital Equipment/DoD/Aerospace Industry-

Manufacturing Group Manager: Manage and direct Machining, Tool Shop,

Metal Fabrication, Paint, Stamping, Gun Assembly, Transformer Assembly,

Electronics, Wire/Cable and Harness Assembly Departments, up to 450

employees, 14 supervisors and leads.

Manufacturing Engineering Supervisor : Manage Manufacturing Engineering

Department, 4 Manufacturing/Industrial Engineers. Core team member of

AS400 MAPICS MRP implementation.

Lead LEAN in the following areas PWB assembly, machine shop, fabrication

department, wire and cable fabrication, harness assembly, gun assembly,

transformer assembly and stator assembly areas. Implemented cellular

manufacturing, kanban, 5S, SMED, visual management, Poka-Yoke, and problem

solving.

Project Management Accomplishments:

Capital Equipment: FinnPower Turret/RT Angle Shear FMS, Cincinnati Laser,

Motoman Robotic Welding Cell, Cincinnati 4" Press Brake, (2) Hager

Presses, (2) Nordson Powder Coat Booths, 6 Stage Wash/Treatment System,

Traub CNC Turning Center, Toyoda VMC, (2) Mills, Davenport Screw Machine,

Minster Punch Press, Durant Feeded/Straightener, CHAD Industries Odd Form

Insertion Machine, Universal 140 Station Insertion Machine, Eubanks Wire

Processing Equipment

Building: Facilities Layout, Facilities Consolidation

Continuous Improvement: Training and implementation of LEAN tools

including cellular manufacturing, 5S, kanban, waste identification and

elimination, SMED

Processes/Equipment: Sheet Metal and Structural Metal Fabrication, Laser,

Turret Press, Press Brake, Stamping Presses, Tube Cutting, Tube Bending,

Robotic and Manual Welding, CNC & Manual Machining; Powder Coating; Wire,

Cable & Harness Assembly; Transformer and Chock Assembly; PCB Assembly;

Assembly.

Aerovent Inc, Piqua, OH $175M Sales Multi-facility

Operations (2) 1985 to 1989

Industrial Engineering Supervisor

Manufacture of Industrial Material and Air Moving Equipment-HVAC/Capital

Equipment/Construction Industry

Manage Industrial Engineering Department, responsible for two (2)

facilities, Core team member for AS400 DATA3 MRP implementation. Two (2)

Industrial Engineers, Three (3) IE Technicians. Activities included

development and implementation of mfg cells, visual management boards,

kanban, Poka-Yoke and SMED.

Processes/Equipment: Sheet Metal and Structural Metal Fabrication,

Welding, CNC & Manual Machining; Paint and Prep; Wire and Cable & Harness

Assembly; Assembly.

USAF 1978 to 1985

E-5- Management Engineering-Manpower Management Technician : Conduct SAC

and Air Force Management Engineering Agency directed studies at base

level. Prepare and coordinate manpower standards development reports and

manpower standards application project for a duel-wing installation.

Provide management advisory and consultant services to wing and

subordinate unit commanders and managers.

Medical Service Technician: Assist professional medical staff in the

treatment of patients in the Medical/Surgical Ward, Emergency Room and

various clinics

Key Words:

Automotive, Aerospace, Defense, Military, Specialty Vehicle,

Telecommunication, Power Generation, Capital Equipment, HVAC, Appliance,

Certified Lean/DFSS, Six Sigma Green Belt, DMAIC, Value Stream Mapping,

Cellular Manufacturing, Kaizen, Kanban, 5S, SMED, 5 Whys, Employee

Relations, Profit & Loss, Revenue Growth, Value Stream Mapping, Project

Management, Change Management, Multiple Facility, Expansion, Strategic

Planning, Tactical Planning, ERP, MRP, ISO9000, QS9000, Safety, OSHA,

Environmental, EPA, Turn-around Management, Quality Improvement,

Manufacturing Engineering, Industrial Engineering, CNC Machining, Manual

Machining, Metal Fabrication, Stamping, Welding, Fiberglass, Wet Paint,

Powder Coating, Printed Circuit Board, Wire & Cable, Harness Assembly,

Custom Assembly, High Volume Assembly, Printing, Cabinet Making, Coil

Winding, Transformer Assembly, Armature, Stator, MBA, BS

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