WILLIAM T. ROYALS

*** **** ****** *****

Hot Springs, AR 71913

870-***-**** (cell)

acqgph@r.postjobfree.com

HANDS ON LEADER WORLD-CLASS OPERATIONS

Innovative Leader with achievement record in quick-turn, high-technology manufacturing environments. Extensive experience orchestrating production turnarounds resulting in millions of dollars in cost reductions, improved revenues, and optimum workforce utilization. Proven ability to analyze operations, supply chain and growth opportunities, and strategic and tactical solutions that improves competitive performance while increasing revenues and reducing costs. Recognized for successes in training, development, and cultural transition of management, engineering, and production teams that result in implementation of world-class safety and quality standards.

Lean Manufacturing - Takt, Pull, Flow

Continuous Improvement

Process Enhancement

Shop Floor & Business Process Kaizen

Union & non-Union Employee/Management Relations

Supplier/Partner Negotiation

Environmental, Health, Safety, & Sustainability Improvements

Supply Chain Management

Training Champion

APQP Experience

EXPERIENCE

KOHLER COMPANY – KITCHEN & BATH, Kohler, WI 6/2004 – Present

Multi-billion Sector specializing in highest quality, competitive, avant-garde design faucets, fixtures, and accessories for the Kohler brands.

Director, Arkansas Faucet Operations

Responsible for total operation of multiple high volume plants and distribution center supporting faucets, accessories, and injection molded products through retail and wholesale channels. P&L responsibility for $350M/yr annual operations with over 800 employees in both union and non-union environments.

Improved line item on time in full on-time delivery from <70% to over 95%.

Delivered over $6M per year in total direct & indirect CI savings. Established full-time Office of Continuous Improvement using Yellow, Green, & Black Belt approach as well as Shainin Red-X.

Reduced RIR and DART rates by 10x. Established Safety and Environmental teams in every plant focused on accident elimination, resource conservation, and return to work initiatives.

Reduced scrap by over 50%. Utilized DMAIC process to drive out scrap through process control and capital investment.

Reduced Time-to-Market from over 30 months to 12 months for new product introductions. Set-up NPD focused operation driving down cycle time with concurrent engineering and DFx.

Improved labor productivity net of inflation for 4 consecutive years. Multiple Automation Implementations

Implemented SAP based multi-year forward looking equipment & labor capacity forecasting system. Led Supply Chain redesign using SCOR model

Responsible for the Global Faucet Cost Reduction initiative as global champion of the task force

oAchieved over $7.5 million in product and over $10 million in process savings annually across multiple faucet business locations globally.

oDeveloped a globally scalable Cost Reduction System (CRS) - holistic analysis of costs drivers and a cross-functional decision making process to ensure product and manufacturing process changes chosen provided an overall economic benefit to the business.

William Royals Page 2

UNION METAL CORPORATION, Canton, OH 1/2003 – 2/2004

$55 million operation specializing in the manufacture, assembly, test, overhaul, refurbishment and service of poles for traffic lights, roadway lights and signs, area lights, cellular communications, and other commercial applications throughout North America.

Vice President, Operations

Responsible for entire production operation, including engineering, quality, manufacturing, material, facilities, and logistics.

Instituted scheduling discipline and structured dispatch policy that reduced lateness from 600 orders and 6000 production units to 17 orders and zero units.

Increased production 33%

Reduced major equipment downtime 75%

Decreased labor costs 25%

Reduced lead times 50%

Lowered subcontractor costs by 30% in 12 months.

PRATT & WHITNEY - SPACE PROPULSION, West Palm Beach, FL 10/1986 – 1/2003

$350 million division specializing in the manufacture, assembly, test, overhaul, refurbishment and service of rocket engines, rocket motors, valves, actuators, turbo pumps and other high tech electronics.

Director - Manufacturing & Test Operations,

Led cross-functional team of 500 employees (engineers, analyst, technicians and mechanics) across 3 sites (FL, AL, CA) with demonstrated mastery through all aspects of production operations and product line delivery performance. With a $24 million monthly budget and 12 direct reports, instituted sweeping changes ensuring optimization of systems, processes, workforce, and resources across the supply chain operation, manufacturing, assembly and testing to exceed customer quality, service and delivery expectations; met/exceeded all internal cost initiatives, performance improvement strategies, and revenue and profitability goals for exceptional results.

Accelerated career through engineering and engineering management positions with a successful transition in 1994 from space operations to manufacturing, assembly and test operations. Promoted to Director and quickly became recognized as a top performer with high-level professionalism and business acumen.

Reduced indirect budgets more than $750,000 through effective TPM and OEE implementations.

Developed business, financial, and operational plan to rationalize 11 disparate locations into 1 consolidated operation in Florida. Obtained $15 million budget approval and built effective partnerships with state and local officials for noteworthy grants, rebates, and incentives. Without disruption in quality and delivery performance completed project ahead of schedule and 15% under budget. Plan resulted in attainment of all cost-reduction targets and corporate business plan objectives, with high customer accolades.

Directed internal and external teams through sweeping continuous process improvement changes and implementations. Introduced Lean manufacturing principles, kaizen activities, and flow lines processes, reducing total cycle time from 52 weeks to 16 in one product area and from 30 days to less than 10 in another, while reducing touch labor 40% per unit.

Achieved ISO9000:2000 and AS9100 registration at 2 sites with only one finding. Across all sites maintained Lost Time, OSHA Recordable and Total Injury Rate at world-class levels while at the same time established systems to attain ISO14001 registration and Cal-OSHA VPP Star.

William Royals Page 3

Unit Manager - Assembly & Test Operations

Unit Manager - Test Operations

As Unit Manager of combined operations, managed $6 million monthly budget and 200+ labor, technical, and engineering personnel, responsible for assembly, quality, scheduling, test and delivery for engine and turbo machinery. Initiated assessment of skills, process, functionality, and cost efficiency of separate test and assembly operations, resulting in recommendation and approval to consolidate these business units, saving nearly $500,000 annually.

Within the first 12 months successfully reduced inventory $5 million and assembly WIP 75+%. Introduced Toyota Production System principles, which immediately reduced per engine assembly cost 25%. Combined efforts reduced assembly and test cycle time from 45 to 15 days (67% reduction).

Championed corporation’s first Certification/Qualification program and created/implemented first Standard of Work. Designed formalized employee development plan; recommended and instituted complete Job Safety Analysis Program, and established on-line training/certification program for mechanics, technicians, and engineers.

Improvement strategies resulted in 20% employee participation in degree-granting programs and achievement of substantial improvement in environmental, health, and safety performance. The business unit achieved zero lost time accidents over 60 months and world class OSHA recordable rate.

Cell Leader, Manufacturing – Space Operations

Supervisor, Manufacturing Engineering – Space Operations

Senior through Project Engineer – Government Engines

LITTON INDUSTRIES, INGALLS SHIPBUILDING

Progressed from Associate Design Engineer to Lead Design Engineer

EDUCATION & PROFESSIONAL DEVELOPMENT

Master of Science, Global Supply Chain Management, Indiana University, Bloomington, IN

Master of Science, Manufacturing Engineering, Boston University, Boston, MA

Bachelor of Mechanical Engineering, Georgia Institute of Technology, Atlanta, GA

Memberships and Significant Accreditation

President, United Way of Grant County Arkansas

Director, United Way of Southeast Arkansas

Trained Kaizen Facilitator; Continuous Improvement Processes

Job Hazard Analysis Training

ASTM Committee Chairman; Compatibility and Sensitivity of Materials in Oxygen Environments

UVA Darden School, Executive Education Progra

Kohler Leadership Development Program

SAP & Oracle ERP Implementation

Professional Engineer, State of Florida

Pratt & Whitney Diversity Council

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