James Fairchild

*** ***** *****, *** *****, PA **072

Cell: 908-***-**** (acechn@r.postjobfree.com)

MANUFACTURING PRODUCTION MANAGER / DIRECTOR

Highly experienced manufacturing manager with over 25 years' experience in

production, accounting, distribution, continuous process improvement and Q

/ C. Background includes managing manufacturing operations of a Fortune

500 company in water and sewer piping within the water works industry.

Known as an energetic proactive, results oriented individual that interacts

well with all organizational levels, coupled with a very high work ethic

within a team effort as well as an independent contributor. Expertise

includes:

Lean Manufacturing ISO 9000

Six Sigma Manufacturing Accounting

Plant Management Training

Problem Resolution Quality Assurance

Analytical Skills Manufacturing Management in a Union

Environment

Process Improvement Root Cause Analysis

PROFESSIONAL EXPERIENCE

Atlantic States Cast Iron Pipe Co., Phillipsburg, NJ

1987 - 2014

A division of McWane, Inc., a major national producer of ductile iron

pressure pipe, fittings, valves, and hydrants. Employing over 250 people,

producing pipe sizes from 3" - 24" in diameter.

Continuous Improvement Manager 2011 - 2014

Resulting from the successful efforts in improving production capabilities

in the Melting and Centrifugal casting areas was asked by senior management

to begin focusing on the continuous improvements of production for multiple

depts. Led the development and implementation of ongoing continuous value

improvements, including assessments, reports, training, and recommendations

for operational and cost reductions.

Accomplishments:

. Using A3 thinking (Lean Mfg.), created teams for process and cost

improvements such as:

. Reducing Magnesium costs by over 30% while decreasing the rework in

the finishing dept. with an annual savings of $300K

. Increased thru put from 140 to 180 pcs / hr. in the cast operations by

designing a system of oven loading sequencing, which increased the

production capacity, resulting in over $1M potential savings.

. Reduced Fuel costs by 20% using alternate fuels and lowering the

amount of coke per charge.

. Implemented a new core gas train and handling system that reduced the

production scrap by 50% while virtually eliminating all overtime in

the core department, resulting in over $650K in savings.

Production Manager 2009 - 2011

Asked by senior management to take on new assignment focusing on difficult

problems in the Cupola Melting and Centrifugal Casting operations,

including Annealing. Primary focus on Cost reduction and efficiency

improvements on the hot metal side of operations.

Accomplishments:

. Directed and implemented a cupola lining project that greatly reduced

coke consumption while increasing silicon recoveries in the base iron.

Coke to iron ratio went from 6.84 to 8.37, savings of approx. $100K /

month.

Atlantic States Cast Iron Pipe Co., Production Manager (continued)

. Installed a cupola tuyere injection system, allowing the use of

alternate materials to be injected directly into the melt zone which

increased silicon recoveries by 14%, resulting in over $250K savings.

. Due to production supervisions' insufficient knowledge of various

production processes and procedures, causing excessive slowdowns and

scrap items, developed and delivered training programs to increase

knowledge levels which resulted in increased production and decreased

scrap rates.

Plant Manager 2004 - 2009

Responsible for Production, Quality, Maintenance, and Engineering

facility, including Shipping / Receiving, with over 50 direct / indirect

salary reports and 270 production employees.

Accomplishments:

. Designed and implemented a second finishing line that increased thru

put, reducing overtime by 50% with an annual savings of $250K.

. Successfully created a second shift production line to meet increased

customer demands.

. Assisted in design and managing the first cupola melting bag house

emission system which virtually eliminated all mercury emissions which

was featured on the cover of Foundry Magazine in Oct. 2005 and

Manufacturing Today in April 2006.

. Implemented a water based asphaltic paint system that eliminated all

volatile organic compounds (VOC) emissions.

Quality Assurance Manager 1997 - 2004

Responsibilities included developing and installing a new quality control

department, having support staff of 13 salary employees.

Accomplishments:

. Worked with other staff within the organization to determine and

establish procedures for quality standards and monitoring process

against targets.

. Set up and established the first McWane quality management system

providing an ISO 9000 certification within six months.

. Decreased customer complaints by 50% within the first three years.

Cost Accountant 1987 - 1997

Responsibilities include daily analysis of process costs activities using

data accumulation systems, inventory evaluations, and production reporting.

Monthly reporting of Variances, FIFO inventorying methods, and monthly

cost reports.

Accomplishments:

. Updated computer processes within the accounting, sales, purchasing,

HR, and shipping departments.

. Accepted into the management training program, attended college for

engineering, and obtained Master's degree while performing job duties

full time.

EDUCATION

Lafayette College (1992 - 1997)

Mechanical Engineering (shy of 30 credits)

Wilkes University (1989 - 1992)

Master of Business Administration (MBA), Accounting and Finance

Alvernia University (1985 - 1987)

Bachelor of Arts (BA), Accounting

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