JOHN T. BIRES

**** *********** **** • Baldwinsville, NY 13027 • 315-***-**** • acuz24@r.postjobfree.com

QUALIFICATIONS SUMMARY

Manufacturing Operations, Engineering, and Quality Manager with 25 years experience implementing best practices within 8 industries. Great leader and change agent with a friendly, collaborative leadership style. Strengths include Lean Manufacturing and Six Sigma implementation, new product and process design and introduction, cost reduction, team leadership, and plant operations planning and execution.

CAREER HIGHLIGHTS

7 years experience as a director of manufacturing / facility manager with the majority of my 15 years management experience in high-volume/fast-paced environments working with a diverse workforce.

Led a Lean Transformation at Oneida Air Systems that resulted in reduction of time to ship customer orders from 2-6 weeks to 1-3 days; reduction in FG inventory by 70%, labor reduction of 35%, space reduction of about one-third, and workmanship defects reduced by 67%. Lean Six Sigma skill level equivalent to an advanced black-belt.

Strong customer focus as demonstrated by numerous quality improvements including a 50% reduction of customer warranty returns within 18 months at Allied Motion.

Have had full P&L responsibility at two facilities as well as my own small business – skillful at financial analysis, budgets, capital planning, etc.

WORK EXPERIENCE

Allied Motion, Watertown NY 2014 - 2016

A manufacturer of motion control products for industrial, medical, and defense industries.

Operational Excellence Manager

Led the continuous improvement and quality assurance functions. Using a collaborative approach developed and implemented plans to improve quality, cost, and service.

Reduced customer returns by 50% and internal defects by 56% by developing and executing a “Quality Roadmap”.

Improved on-time delivery from 79% to 91% by separating production planning processes for Runners and Repeaters (R&Rs) from Strangers. Production of R&Rs was then converted from Push to Pull by implementing a system of kanban supermarkets at key decoupling points.

Changeover times were reduced from 10hrs to 2hrs at the bottleneck operation.

Transformed the visual appearance of the facility by implementing a 5S program, developing a suite of visual metrics, and installing TV monitors at each workstation to display SPC charts in real-time. Visual management was then used for daily decision making and monitored with a “Gemba Walk” that I led on a daily basis.

Parker Hannifin Aerospace Division, Clyde NY 2011 - 2013

A manufacturer of fuel nozzles for commercial and military aircraft engines.

Value Stream Manager

Led two production teams and a quality inspection team. Managed 11 exempt and 85 non-exempt employees, and a $3.5MM expense budget.

Using Theory of Constraints methodology, improved on-time delivery of the GE90 team from being the worst in the facility to having a perfect on-time record.

Created high performance work teams resulting in production teams being more self-directed.

Led lean initiatives including visual management, work cell redesign, improved flow, standard work, and maintenance of value stream maps.

Led X-ray and Fluorescent Penetrant Inspection team in executing and improving all aspects of operation.

Oneida Air Systems, Syracuse NY 2006 - 2011

A manufacturer of cyclonic dust collection systems.

Plant Manager

Led Oneida in overhauling their manufacturing and shipping operations.

Led a Lean Manufacturing transformation resulting in reduction of time to ship customer orders from 2-6 weeks to 1-3 days; reduction in FG inventory by 70%, labor reduction of 35%, space reduction of about one-third, and workmanship defects reduced by 67%.

Created and implemented a custom MRP system that has allowed the company to virtually eliminate part shortages.

Overhauled safety program, bringing the company back into OSHA compliance. OSHA DART rate was improved from a dismal 14.8(2006) to 5.9(2007) to 1.9(2008) to a perfect score of 0.0(2009).

J&S Enterprises, Baldwinsville NY 2000 - 2006

A $1 million distributor of preventative health and nutrition products.

Business Owner

Established a successful small business marketing a line of preventative health products. Expanded operations nationally through a network of sales reps that were recruited and trained. Awarded “Millionaire Team” status by parent company in 2004 for performance in the top 1% of over one million distributorships in 60 countries.

OSMONICS, Liverpool NY 1997 - 1999

A manufacturer of water purification and filtration components.

Plant Manager and Technology Manager

Developed strategic plans for all aspects of Liverpool operations. Led management team in resolving critical issues and achieving business imperatives. Managed 30 exempt and 90 non-exempt employees, and a $2.7 million budget.

Improved on-time shipping performance of 5 product lines from 75% to 95%.

Increased sales by 23% by implementing a strategic customer service initiative.

Increased staffing from 50 to 120 to accommodate sales increase and transfer of product lines.

Developed and implemented a high performance management team through critical staffing changes and alignment with new business plan.

Developed a comprehensive program to reduce the unit cost of Home Reverse Osmosis elements from $13.50 to $7 to make Osmonics price competitive in Asia and stay ahead of price erosion.

Created, developed and implemented a preventive safety program.

3M COMPANY 1982 - 1997

Process Engineering and Quality Control Manager, Household Products Div. 1994 – 1997

Chemical Development Supervisor, Cardiovascular Devices Division 1992 – 1994

Senior Process Development Engineer, Dental Products Division 1986 - 1991

Advanced Process Engineer, Printing Products Division 1982 - 1986

Supervised 21 engineers and lab technicians.

Conducted Design of Experiments to gain better process understanding, improving production yield and final product quality.

Designed an improved oxygen sensor that is used during open-heart surgery. I received an international engineering award as well as the prestigious Process Technology Award from 3M for this work.

Led cost savings team that reduced costs by $1.1 million (2 times team's target), leading the way for Dental Product's first place finish in the company.

EDUCATION & PROFESSIONAL DEVELOPMENT

APICS CPIM certification in Production and Inventory Management expected 2016

3P Production Preparation Process workshop 2015

Co-authored IPv6 Primer– a computer technology textbook being sold on Amazon 2014-2015

Leading Continuous Change - leadership development program 2013

High Performance Teams – leadership training program 2013

Lean Boot Camp I, II, and III – Lean Manufacturing Training Program 2012

Toyota Production System – self training 2006-2011

Theory of Constraints management – self training 1997-1999

3M Corporate Process Technology Award 1995

International Taguchi Symposium "Excellent Paper Award" 1993

Taguchi Methods, Basic, Intermediate, Advanced Workshops 1992

3M Dental Products Process Development Award 1992

Quality Function Deployment 3-day Workshop 1991

3M Dental Products Process Engineering Award 1989

3M Golden Step Award, P-50 Restorative 1988

Six Sigma Methodologies – completed entire syllabus offered at 3M company 1983-1989

B.S., Chemical Engineering - University of Rochester, Rochester, NY 1982

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