David Grostic acqxmx@r.postjobfree.com

**** ********** ****, **********, ** 60538 630-***-**** (H) / 630-***-**** (C)

Plant Manager

Budgets / P&L / Strategy / Sales Growth / Finance / Cost Control / Gap Analysis / ERP / ISO9000 Quality Systems / EH&S / Site Leadership / Supply Chain Mgmt / Distribution / Logistics / KPI Metrics / MRPII / 5S / Lean Six Sigma / Eliminating Process Waste / Value Stream Mapping / Employee Development / Training / Accountability / Team Problem Solving / Project Management / Process Excellence

Through keen evaluation and business acumen, I have turned around enterprises, increased productivity and maximized profits, positively impacting both the top and bottom lines. Controlling costs in all areas, I analyzed processes and employed Lean methods in electronics, computer, distribution, supply chain, automotive and aerospace companies.

Creating strategies for sales growth in multiple business areas to ensure long-term sustainability

Turning around operations, implementing strategies and starting up new facilities in USA and Mexico

Documenting and streamlining assembly processes of highly engineered electro-mechanical products

Ensuring compliance with regulatory agencies with keen focus on corporate goals and mandates

Building loyal and dedicated high performance teams with six sigma training to perform at their peak

I earned an MBA from the University of Missouri and a BA in Economics from Saint Michael’s College. I graduated from General Electric’s 2-year Manufacturing & Engineering Management Program.

Peers have noted that as a problem solver, I work well as part of a team. Easily winning people’s confidence, I meet demanding objectives in rapidly changing environments. Known as a friction-free team player and loyal dedicated leader.

Fundamental Skills: Six Sigma Black Belt and Lean Six Sigma Blue Belt Certified, ISO9001:2008 Quality Management Systems Expert/Auditor, Veteran ERP/MRP User (SAP & Oracle) and DMAIC Team Based Problem Solving Leader.

Career History and Selected Accomplishments

Principal/Co-Owner, Orion Solutions LLC, Montgomery, IL, 2012 to Present. Helped establish family owned company offering contract process excellence consulting and client support services.

Established sales, forecast, operations, finance, training and annual budgets for small business owners

Implemented performance metrics (KPIs) for client to drive change, increase productivity and accountability

Launched new ERP/MRPII System for large warehousing client to integrate all business functions (end-to-end)

Currently Pursuing Opportunities. Have decided to pass on Orion duties to extended family members and pursue more stable opportunities in plant management, manufacturing operations and process excellence. Currently available.

Site Director, CommScope, Joliet, IL ($3B telecommunications manufacturing company), 2011 to 2012. Responsible for heavy cable manufacturing and CNC machining operations and North American Distribution Center.

Products: Copper based heavy cable, machined connectors, custom cable/connector and backplane assemblies

Held full P&L responsibility for the division ($200M)

Ensured production goals and service level agreements (SLAs) were met

Drove change by implementing process improvements using Lean and Six Sigma techniques

Oversaw CNC machining centers, tool and die making, cable manufacturing (extrusion, welding, molding)

Supervised resource scheduling to meet shift and demand planning requirements

Implemented and analyzed KPI metrics, produced cost forecasts and reviewed performance gaps monthly

Managed 7 direct reports (production, engineering, quality, maintenance, planning, warehouse, procurement) who managed 300-350 employees

Controlled costs during company restructuring. CommScope’s business shrank pursuant to a 300% rise in materials costs (mainly copper). Reduced headcount 35%, offering early retirement packages to many employees. Changed shift schedule from 5 days/3 shifts to 4 days/2 shifts. Reduced operating costs $12M by lowering labor and overhead cost. Reduced inventory levels by 32% and doubled inventory turns on targeted commodities. Drove order to cash cycle down from 6-8 months to 2-3 months by implementing “build-to-order / cut–to-length” business model versus historical “build-to-stock” business model.

Director of Operations, Control Solutions, Aurora, IL ($110M aerospace/medical electronics company), 2008 to 2010. Duties included all company manufacturing, quality and supply chain management including plant start-up of 2 facilities.

Products: Military/Medical/Industrial grade programmable DC Motor Controller Electronic Systems

Designed plant layout and assembly lines (PCBA, cable, potting, mechanical assembly and test)

Documented assembly and test processes to support ISO9001 foundation and Mil-Spec quality requirements

Drove implementation of new Oracle ERP system to integrate all functional areas (company had no prior system)

Set-Up material requirements planning (MRP) schedule and created production forecast for military customers

Ensured ISO/FDA/Department of Defense (DoD) quality standards were met (passed all 3rd party audits)

Established supply chain, procurement, warehouse, distribution and logistics/transportation operations

Ensured compliance with government contracts and federal/state/local regulations

Managed $80M operations budget with 8 direct manager reports who oversaw 85 employees

Gained regulatory approval in two new plants. Control Solutions needed to pass audits by DoD and FDA to meet contract requirements in two new manufacturing plants. Formed cross-functional Kaizen teams to analyze audit criteria and form action plans. Implemented ISO9001 and AS9100 standards. Gained FDA and DoD approval on first audit.

Site Director of Operations, ModusLink, Carol Stream, IL ($1.3B supply chain management and 3PL company), 2001 to 2008. Site leader responsible for managing all plant manufacturing operations, distribution and fulfillment.

Products: Supply chain and 3PL services, manufacturing, merchandizing display assembly, high volume automated CPG packaging, vendor and materials management, e-business, call center, value-added client services

P&L and Budget responsibility ($75M division located in Carol Stream, IL)

Designed plant layout, defined/documented all equipment requirements and process flows under ISO structure

Analyzed KPI/metrics, continuous improvement projects and participated in daily 5S plant walk-around audits

Drove lean manufacturing programs to streamline processes (i.e. eliminate waste) and optimize throughput

Ran manufacturing, distribution, fulfillment, transportation, logistics, inventory KANBAN pull systems and MRP

Lead position in plant managing 6 direct report managers who oversaw 500+ employees during peak periods

Launched new facility in record time. ModusLink gave me five weeks to open a new manufacturing plant and deliver client’s new product launch. Acquired and installed seven manufacturing lines in empty warehouse. Set up IT network and ERP system. Hired 150 employees and trained everyone in lean and continuous improvement manufacturing techniques. Successfully completed 750,000 units first week of operation exceeding client’s expectations.

Senior Manager Systems Engineering, Dell Computer, Austin, TX ($30B computer company), 1999 to 2001. Managed program office for new product introduction (NPI) of server and storage devices. New market for Dell.

Products: Servers, storage devices and diagnostic software supporting a global marketplace

Drove full new product lifecycle, from design concept, prototyping, manufacturing testing and market launch

Managed supply chain partners and component testing in Dell’s system development labs

Led team of 8 program managers and 20 support project planners and diagnostic test software developers

Met aggressive production schedule. Dell planned to release up to 30 new product platforms per year. As a new division, few controls were in place to leverage best practices, tracking and repeatability. Devised an integrated program monitoring system based on use of MS Project Scheduler to track multiple target dates, resources and task-driven program milestones in real time. Successfully launched 70 new products in 2 year period exceeding all program goals.

Plant Manager, SPX, Auburn, IN ($1B Tier 1 automotive aluminum die casting factory), 1998 to 1999.

Products: Aluminum die cast automotive parts (steering and suspension components) for Ford, GM, BMW & Honda

Die cast production (18 – automated robotic die cast component manufacturing cells running 3 shifts 24/7)

Inventory control and JIT delivery (same day build and ship business model to Ford and GM)

Human resource administration, EH&S and employee development

Managed and responsible for all functional areas of the plant

Implemented Total Productive Maintenance (TPM) Program

Heavy focus on Environmental, Health & Safety Compliance

Quality (QS9000 and ISO9000 Certified)

Avoided unionization. Experiencing low morale due to perceived corporate indifference to safety issues and work conditions, employees were considering unionization upon my arrival. Established anonymous survey, performed root cause analysis on each complaint and outlined corrective measures. Invited OSHA to perform assessment and launched a Total Productive Maintenance program. Engaged and Trained employees in Kaizen methodology. Defused union push.

Director of Operations, Clarostat Sensors & Controls, El Paso, TX & Juarez, MX, 1994 to 1997. Managed 3 “maquiladora” manufacturing plants ($75M P&L) in West Texas border region.

Products: Industrial and military grade potentiometers, thermostatic controls, variable resistors, optical encoders, fiber optic sensors, light curtains, multi-function push buttons and switches, trimmers, slide controls, fiber optic smart controls

Managed all production and plant operations on both sides of the border

Drove project to achieve ISO9001 certification and successfully passed first audit

Led CNC machining, metal fabrication and plastic injection molding plant in El Paso feeding Juarez plants

Created procurement, supply chain, global sourcing and contract negotiation strategies and partnerships

Controlled inventory (accuracy and KANBAN lean levels) and daily border logistics

Measured Key Performance Indicators (KPIs), Daily Performance Dashboards and Order to Cash Cycles

Drove dramatic growth with new products. As Acting Division President at Clarostat, challenged to increase revenue. Instituted SWOT analysis with senior managers. Formed new R&D group and created four new products. Grew sales 20% and EBITDA from 8% to 12% over 10 months, while older core products were declining up to 15%.

Saved thousands completing project ahead of schedule. Tasked by Clarostat to move 3 US based manufacturing plants to the El Paso/Juarez region in 18 months with $170K budget. Re-engineered processes for new facility and workforce, closely monitoring progress. Started operations three months ahead of schedule, saving $31K in labor costs.

Early Career (1979 to 1994)

General Manager, Chloride, Rochester, NY/El Paso, TX/Juarez, MX (1991-1994) – Electro-mechanical Power Products

Sr. Mfg. Manager, General Electric, Burlington, VT/Syracuse, NY (1985-1991) – Gatling Guns, Sonar/Radar Systems

Buyer/Planner, Digital Equipment, Marlboro, MA – Mainframe Computer Systems and Operating Software

Minuteman II, ICBM Strategic Launch Officer, Rank - Captain, U.S. Air Force – Whiteman Air Force Base, MO

Education

MBA – University of Missouri - Columbia

Bachelors of Arts (BA) – Economics, Saint Michael’s College – Colchester, Vermont

Graduate (2 year) - Manufacturing & Engineering Management Program – General Electric Training Department

Special Technical Skills

Industry Experience – Aerospace/Defense, Automotive, Logistics, Warehousing, Distribution, Supply Chain Services, Computer Software & Hardware, Consumer Electronics, Retail, Telecommunications and Consulting

Security Clearances Held – Top Secret ESI Level 6 (USAF) and Secret (GE Aerospace, Chloride Power Electronics)

Certifications - Six Sigma Black Belt & Lean Six Sigma Blue Belt Certified

Strategy - P&L Budgets, Sales Strategy, Strategic Planning, Annual Operating Plans, Channel Marketing Plans

ERP, MRP and WMS - SAP, Oracle, Exceed, MAPICS, IFS, Access, Queries and other home grown systems (i.e. DELL)

Expert Hands-On User - Microsoft Office Products (Excel, Word, PP, Access, Outlook), Lotus, Word Perfect, Vizio

Quality Systems - ISO9001, AS9100, QS9000, ISO14001, TS16949, OSHAS18001, FDA, Military Compliant Standards

Warehouse Ops - Receiving, Inspection, RF & RFID Systems, Inventory Control, Picking, Kitting, Packing and Fulfillment

Inventory Control – Cycle Counting, FIFO, Physical Inventory, Space Optimization, RF Scanning, RFID, Turns Metrics

Employee Engagement - All Hands Meetings, Shift Start Meetings, 5S Audits, Metrics, Gap Reviews, Gemba Walks

Supply Chain Mgmt - Scorecards, Partnerships, Audits, Sourcing, Bid/Proposal, Negotiations, Service Level Agreements

Problem Solving - Kan-Ban, Pull Systems, Kaizen, DMAIC, 5-7S, 5 Whys, Value Stream Mapping, TPM, SMED, SOPs

Compliance Programs - EH&S, EPA, HAZMAT, MSDS, DoD, UCC, Injury Free Workplace Practices, Green Programs

Processes – CNC Machining, Injection Molding, Aluminum Die Casting, Electro-Mechanical Assembly, Metal Fabrication

Department Mgmt Experience – Sales/Marketing, Manufacturing, Quality, Design Engineering, Process/Test Engineering, Account Management, Purchasing, Inventory, Continuous Improvement, Facilities, Maintenance, Tool/Die Making, Warehousing, Distribution, Inventory, Demand Planning, Program & Project Management, HR, IT and Finance

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