ANDREW MATTY

*** ******** ****** ****: 614-***-****

E-Mail: abnmm3@r.postjobfree.com

Powell, Ohio 43065 Cellular: 614-***-****

www.linkedin.com/in/skipmatty

DIRECTOR - LEVEL OPERATIONS PROFESSIONAL

Successful Leader of Engineering, Quality, Operations, & Manufacturing Teams in High-Tech Environments

Expertise in Lean Manufacturing • Six Sigma Black Belt Trained

AREAS STRENGTH & EXPERTISE

OF

• P&L Administration • Policy/Procedure Development • Printing Systems

• Startup/Turnaround • ERP (Infor Baan IV and Baan LN) • Injection Molding

• Quality Control • Capital Equipment Budgeting • Lean Manufacturing

• Facilities • Manufacturing Systems • Supply Chain Management

• Capital Budgeting &

Management Development

• Materials • Vendor/Supplier Management Expenses

• ISO/Quality Management Systems • Staff Training &

Management

• Process • Continuous Improvement Principles Development

• Facility Safety/Security

Improvement • Preventative/Predictive

• GMP • Workflow Management

Maintenance

• Cost Review • Purchase/Contract Negotiation • Packaging/Distribution

• Expense Control

PROFESSIONAL EXPERIENCE

JET PLASTICA … Hatfield, Pennsylvania February 2009 to August 2009

Manufacturer and packager of plastic cutlery, straws, and utensil kits; $160+ million annually with 500+ employees

in two facilities; provider to all major restaurant and food supply services companies.

Production Manager

Ensure quality, process improvement, adherence to GMP standards, and daily production throughput for

the manufacture and packaging of polystyrene and polypropylene cutlery and packaged kits; manage

175+ employees across three departments operating 24/5 and 24/7; accountable for all associated department

costs.

Departments of responsibility include injection molding, packaging, cell manufacturing, and mold-shop;

equipment consists of (33) 200-450 tonnage injection molding machines from 4 manufacturers, 11 packaging

lines, 5 cell manufacturing cells consisting of injection molding machines directly feeding packaging lines, and a

mold-shop supporting 62 molds with 24-72 cavities.

Reduced and stabilized injection molding scrap from 7.5% to 5.5%, saving $12,600 monthly in resin costs;

maintained or increased cases/labor hour while orders for cases fluctuated by up to 20% per month.

Original member of Lean Steering Committee created in April 2009; created metrics reporting mechanism for

multiple departments; led and assisted with implementation of lean principles in manufacturing operations.

Key member of Infor ERP LN implementation team; operations department lead/expert; assisted with system

setup; developed and implemented training documentation.

ZOMAX (Formerly Inoveris/Metatec) … Dublin, Ohio 1996 to 2009

Provider of global supply chain management, supply chain outsourcing, retail supply chain distribution, software

supply chain logistics, 4PL, and CD/DVD replication services; generates $150 million annually with 600+

employees.

Director, Manufacturing Operations & Engineering (November 2005 – February 2009)

ANDREW MATTY Résumé Page 2

Develop vision, coordinate strategy and ensure production progression and quality for quick-turn

manufacture of 175,000 optical discs (CDs & DVDs) daily and 25-33 million optical discs annually; manage

$6 million annual operating and capital budget; accountable for profit and loss performance of 24/7 manufacturing

operations (facility considered largest manufacturing and assembly/distribution operations in company).

Operational and support groups/departments comprise pre-mastering/data services; mastering; art

services/graphic arts; replication/molding; manufacturing quality control; screen making & ink; printing; quality

systems; technical support, engineering; distribution and packaging support; facilities support, safety, and

security; equipment ($30+ million value) includes 21 injection molding machines, 13 CD finishing lines, 3 DVD

finishing lines, 8 screen printers, screen making equipment, 5 mastering machines, 2 metallizers, 8 electroforming

plating tanks, 2 imagers/film processors, plastic drying and delivery system, waste water treatment systems, and

security surveillance system.

Direct reports (10) comprise manager, mastering operations & safety support; manufacturing manager;

supervisors/technical specialists; director of quality systems; manager, facilities support; engineers;

indirect oversight for 90+ associates; spearhead staffing functions including hiring and firing, work scheduling,

overtime approvals, and performance valuations.

Scope of responsibilities include manufacturing forecasts, raw materials and supplies procurement, sales

support, major account management, and technical issue resolution (including client site contributions);

simultaneously serve as printing subject matter expert.

• Contributed to initiative saving $4 million annually; amidst purchase of Zomax by Inoveris (and name

change to Zomax), served in lead role evaluating and moving manufacturing equipment to existing Inoveris

sites and remaining Zomax manufacturing site.

Enabled remaining sites to seamlessly move orders, function with consistent quality standards and

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balance capacities by regulating art and print processes as well as disc quality testing procedures.

• Elevated mastering department yields to consistent 91.5% (from 87% average) through collaboration

with mastering manager on project implementing Six Sigma methodology to gather data, analyze results and

develop improvement strategy; results showed within just 4 weeks of preparation, planning and

implementation and ultimately enabled more predictable output and greater output per day.

• Support notable clients including Dell, HP, Apple, CA, Kyocera, HR Block, Webroot, Snap On, John

Deere, GM, McGraw Hill, Glencoe, Knowledge Adventures, Morningstar, Chemical Abstracts, Toshiba,

Alienware, Cummins Engine, Nationwide, Lexicon Marketing, Intuit, and OCLC.

• Facilitated improvement to turn-times, workflow and quality through introduction of 5S lean

manufacturing methodologies; trained team on 5S principles, organized modifications and led

implementation of program (including placement of consistent signage system in all manufacturing areas).

• Spearheaded project enabling facility status as Microsoft Authorized Replicator site; required set up

processes to receive, print, and ship COAs (Certificates of Authenticity), as well as all related security

requirements.

• Coordinated 37% workforce reduction in 2008 (31 employees saving more than $1 million); facilitated

economic rightsizing in 3 stages (to include reduction in non essential operating materials and activities) while

simultaneously maintaining corporate culture in manufacturing.

• Lowered inventory by $400,000 through implementation of inventory system carrying minimal

inventory and JIT system with suppliers for spare parts (available within 24 hours); movement required

in recognition and response to tight financial market.

• Saved $70,000 annually through change of suppliers for CD lacquer and DVD adhesive to single

supplier; saved $2 per kilo of adhesive (12,000 kilos used annually) and $4 per kilo of lacquer (11,000 kilos

used annually).

• Administered $30,000 project reconfiguring clean room areas housing mastering process; included

consolidation of 2 mastering steps, creation of standalone room for duplication project, removal and

reconfiguration of clean-room walls and air handling systems, and addition of electrical and data drops.

• Assisted with development of process moving Computer Associate (CA) direct business to facility;

move required research, purchase, and installation of tape drives for CA enterprise server tape applications.

ANDREW MATTY Résumé Page 3

• Enhanced overall manufacturing operations by fostering culture of continuous improvement

(sustained by using data collection and analysis as foundation for initiatives); ensure constant real-time

web-based data collection and reporting availability providing staff instantaneous ability to analyze and

respond to process requirements and modifications.

• During tenure in position, developed techniques, improved skills and maintained loyalty of entire

workforce as well as enabled several associates to be promoted from within; i.e. mentored direct report

to progressive areas of responsibility (starting as packaging engineer and progressing to art group manager

and packing manager).

• Contained material (nickel) expenses (as nickel rose from $5,000/ton to $30,000/ton) through

negotiation with chemical supplier to purchase volume and release smaller quantities in increments (invoicing

on deliveries).

• Played role in negotiation of cooperative (co-op) pricing and purchases of tens of thousands to

hundreds of thousands of dollars in polycarbonate, ink, lacquer/adhesive, and screens annually; co-op

(formed with disc manufacturers) saved company hundreds of thousands of dollars annually.

• Collaborated with Director of Quality on upgrade to ISO9000:2000 status (from ISO9000:1994 status;

reconstructed existing quality system, developed new processes and procedures, and established quality

council (served as manufacturing representative on company quality council).

• Guided system engineer through continuous build of manufacturing systems using National

Instruments Labview (with systems providing interface between BaaN ERP system and equipment and

operators); maintained expenses to purchase of developer license ($3,000) and desktop computers with

minimal costs enabling elimination of paperwork in manufacturing with real-time data collection and reporting.

Director, Engineering & Technical Services (2003 – November 2005)

Ensured functionality and profit/loss performance of equipment and processes supporting operations

(producing 30-33 million CDs/DVDs annually); administered $1-$2 million operating budget attributed to

salaries, materials, parts, training expenses, and travel expenses.

Supervised emergency and preventive maintenance on manufacturing equipment including 27 injection

molding machines, 10 screen printers, 1 flexo printer, 6 mastering machines, and 16 plating tanks.

Responsible for technical support, engineering, premastering/data services, mastering, art

services/graphic arts, replication/molding, manufacturing quality control, screen making and ink,

packaging/distribution, and printing and quality systems; oversaw 46 staff including technical support

supervisor/technical specialist; replication technical specialist; replication technical specialist; mastering technical

specialists; print technical specialists; shift technicians; replication engineer; systems engineer; systems/electrical

engineer; packaging engineer; engineering interns; manager; technical specialist; operators; supervisor/technical

specialist; art technicians.

• Led 2003 purchase of $1 million DVD replication line (in addition to $50,000 in infrastructure and

$275,000 in test equipment) and 2004 purchase of additional line for $1 million; accountable for project

research, planning and development, technical specifications, install planning, and qualification at

manufacturer site.

• Contributed to analysis and on-boarding of Orem, Utah facility purchased from Saturn Solutions (Q2

2004); enabled company to save $100,000 annually through process established to receive data from Orem

customers, manufacture stampers and ship same day.

• Spearheaded entire scope of projects and initiatives bringing several capabilities to company

including duplication services (replacing disc order replication process); Burn on Demand solution provided to

Getty Images (replacing content ownership issues and errant predictability model previously used);

implementation of high volume digital print on demand model for paper printing.

Projects and initiatives included significant research and testing, equipment and technology

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purchases, process development and transitions, systems integrations, and collaboration with internal

departments and external clients.

• Played instrumental role in maintaining company functionality throughout planned reorganization

(resulting in change to Inoveris); successfully held on to entire client base, earned Best Supplier Award

from customer, secured loyalty of critical staff and collaborated with purchasing department to retain

significant suppliers.

ANDREW MATTY Résumé Page 4

• Collaborated with systems engineers on development of associate performance reports (generated

from data collected through interface programs with ERP system); solution provided critical tool to

supervisors and managers addressing associate output and evaluation.

• Orchestrated purchase, shipment, installation, training and production of machine automating

assembly of DVDs into DVD cases; $600,000 initiative reduced labor from 20+ associates to 5-6 associates

and enabled company to promote competitive packing assembly solution.

• Formed and guided multi-functional team through initiative reducing overruns and underruns;

conducted comprehensive study on entire production process, developed methodology to determine

manufacturing quantity based on order quantity (considering both large and small quantities), and developed

thorough training and education program (provided to customer support, production control and operations).

• Saved $60,000 annually through installation of $5,000 machine enabling recycle and reuse of waste

plastic generated from replication process.

Manager, Engineering (2001 – 2003) (Metatec)

Coordinated, oversaw and contributed to functions including process development and support, capital

equipment purchases and installation, technical support, new product development, supplier interface, and

engineering support provided to sites in Milpitas, California and Breda, the Netherlands; responsible for

department and capital equipment budgeting; delegated tasks to replication engineer, systems engineer,

systems/electrical engineer, packaging engineer, mastering engineer and engineering interns.

• Assisted with standardization and coordination of printing technologies and processes (including

development of standard processes and quality standards) across facilities in Dublin, Ohio, Milpitas,

California and Breda, the Netherlands; led movement of printing equipment throughout sites to balance and

enhance capacities; advised site management on labor, department structure, and hiring.

• Led major projects including reconfiguration and reengineering of manufacturing facility (including

consolidation of replication process with 13 replication machines and printing process with 10

printing machines); outsourcing of screen making process used in printing department (elevating screen

yield from 80% to 98% and saving $565,000 in labor); comprehensive reengineering of printing department

(replacing extremely inefficient operations with several quality issues); development of flexographic printer for

discs (replacing screen printing).

Previously served as Print Engineer (1999 – 2001); Print Manager (1996 – 1999)

EARLY CAREER HISTORY

SAATI (formerly Majestech) … Somers, New York

Technical Representative/CD Specialist (1995 – 1996)

ALLIED DIGITAL TECHNOLOGIES … Hauppauge, New York

Print Process Engineer (1994 – 1995)

KAO INFOSYSTEMS … Lancaster, Pennsylvania

Printing Manager (1990 – 1994)

EDUCATION

FRANKLIN UNIVERSITY … Columbus, Ohio

Candidate: MBA (GPA 4.0)

Bachelor of Science, Double Major: Process Management & Business Administration (GPA: 4.0)

MILLERSVILLE UNIVERSITY … Millersville, Pennsylvania

Bachelor of Science, Industrial Technology with Specialization in Visual Communications

Six Sigma Black Belt Certified

Graduate of Zenger-Miller Front Line Leadership Courses

PROFESSIONAL MEMBERSHIPS

SCREEN GRAPHICS AND IMAGING ASSOCIATION (SGIA) (1990 – 2005)

Winner of Golden Squeegee Awards: Gold 1990; Silver 1991, and Bronze 1991 and 1992

ANDREW MATTY Résumé Page 5

Industry speaker at multiple SGIA events and association training center.

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