Injection Molding Plant

ROGER SCHULZ

*** ******** ***** ? Johnstown ? Ohio ? 43031 ? 614-***-**** ?

aca9kt@r.postjobfree.com

OPERATIONS LEADER

Manufacturing professional with background in high volume plant and

production management, proven track record in safety, lean manufacturing

and process improvement, with the ability to utilize resources to improve

plant productivity, quality, and reduce costs using engineering and six

sigma practices.

COMPETENCIES

Operations management Staff development

Inventory control Policy/program development

Mold and machine R&R Calm professional leadership

Cross-functional team management Green belt training

Proactive safety management

LIQUI-BOX CORPORATION (Formally DuPont Liquid Packaging)

1997 - 2013

Liqui-Box is a world leader in bag-in-box and pouch packaging solutions for

the dairy, beverage, wine and bulk food industries.

Plant Manager

1997 - 2013

Plant Superintendent

1996 - 1997

. Led manufacturing plant consisting of 40 machines and 15 automatic

assembly machines directing activities of up to 140 employees

reporting to Global VP of Manufacturing.

. Developed and implemented hand assembly line for up to 80 temporary

workers to supply new product to customers while new auto assemblers

were being built.

. Led on-site quality assessment of Mexican companies looking for

opportunities to produce at a lower cost. Participated on team that

developed new tooling to reduce assembly from 4 pieces to 2 and

increase production capacity 10 fold. Overall cost of product reduced

in three years from 0.23 each to .04 each resulting in exclusive

supply contract with large global customer.

. Directed strategic initiatives on safety that reduced injuries year

over year, achieving a five year record of no OSHA recordable injuries

and was awarded Dupont Board of Directors safety award twice.

. Sponsored cross functional team projects using six sigma methods to

drive modernization and expanding capacity of facility. Increased

plant efficiency from 80% to mid 90%.

. Led development of business case to purchased new equipment which

reduced overall head count by 50%, saving $3MM annually.

. Utilized statistical quality control to reduce variation in parts from

multiple tooling resulting in better part performance and reduction in

work-in-process inventory by 20%

. Managed plant fixed cost at year over year offsetting annual COL

increases.

. Outsourced tooling with high labor and maintenance costs allowing

scheduling of planned maintenance work in other product lines

resulting in quality performance at six sigma levels.

. Standardized steel sizes on all product components made with multiple

tooling to reduce size variations and ensure proper and consistent

performance on finished product. This also resulted to reduced

interruptions on downstream assembly equipment and easier production

scheduling that increased capacity and utilization in the plant.

. Provided leadership to overseas molding operation upgrade and overall

improvement program, specifying and recommended purchase of molds and

machines. Also determined suitability of local tooling companies to

handle new mold construction and repair. The resulted in significant

cost savings due to reduced oversea shipment to England from US.

. Led plant in implementing DuPont Production System as part of

Corporate initiative to standardize, improve and increase employee

involvement in plant activities.

. Created standard skill level classifications for hourly work force in

order to determine proper pay levels in order to increase work force

motivation to seek skill improvement through educational

opportunities.

Scholle Corporation

1980 to 1996

Scholle is a world leader in bag-in-box packaging for the food, beverage

and industrial markets.

Injection Molding Manager

Injection Molding Supervisor

Injection Molding Technician

. Managed injection molding department of 40 molding machines plus tube

and profile extrude.

. Reduced labor expenses by 30% labor through automation projects.

. Boosted quality performance by mandating use of existing control

systems to utilize unrecognized process benefits resulting in 15%

reduction in rejected product .

. Recommended redesign of existing molds to increase cycle efficiency

and allow for future automation, cost cutting and improvement

projects.

. Led effort to identify and promote more diversity in supervisory roles

in order to more accurately reflect workplace ethnic percentages. Was

able to increase female and minority representation in supervision to

approx. 40%.

. Developed internal training program that developed unskilled labor

into skilled technicians.

EDUCATION/AFFILIATIONS

. Attended multiple colleges. Experience level equivalent of BS in

Plastics Technology

. Instructed classes in Plastics Technology at Northern Illinois

University

. Society of Plastic Engineers

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