Gregory J. Zukowski

Tullahoma, TN

931-***-****

acwafo@r.postjobfree.com

S SUMMARY:

Sr. Production Manager with over 25 years of Operations Management responsibility in highly competitive manufacturing environments. Highly skilled with a track record of significant contributions in Toyota Production System/Lean Manufacturing, “5s”, Kaizen, Kanban, Cost Reduction, Continuous Improvement, Visual Management, Root Cause Analysis and QS/ISO/TS. Particularly effective in improving employee performance by creating an environment for individuals to maximize customer satisfaction. Excellent interpersonal, leadership, problem solving and organizational skills.

ACCOMPLISHMENTS:

As Textron Production Manager, increased production efficiency so that a net yearly $1M profit was realized, from previous multi-million net losses. Responsible for the activities of 2 Shift Superintendents, 10 Supervisors and 250 Employees.

Utilized Toyota Production System/Lean Manufacturing principles to reduce waste (Muda) and thus cost. Principles that were employed included the creation of employee work groups to focus on specific manufacturing and customer needs (Kaizen), the implementation of one-piece-flow through line balancing which eliminated part backlogs and increased productivity (OEE), and the redesign of the production work area which reduced “wait time” allowing for “press side” assembly (rather than at another facility). Visual management techniques were also employed to increase the employee’s part knowledge and to provide a comparison between their performances with the goals. Annual cost reduction savings was in excess of $9,000,000.

Implemented “5s” principles to reorganize work cells, raw materials storage, component storage and packaging storage areas. Additionally, a Kanban ordering system (both card and visual) was implemented both for the reordering of component/raw materials and for production scheduling.

Championed Injection Process Continuous Improvement activities such as the introduction of structural foam as an alternative to gas assist and numerous machine cycle time reductions.

Project and Design Coordinator for the creation of a machine which neutralized flammable production by product. Improved plant safety by reducing the yearly average of low intensity fires from five to zero. This was the first year in the plant's existence where no fires or “near misses” were recorded.

Prepared all plant KPI (Key Performance Indicators) reports on a monthly, quarterly and yearly basis and presented said information to all levels of the organization. Action Plans were developed for any areas that did not achieve target.

As Molding Launch Coordinator, participated in all APQP activities from mold design/product development, DOE’s, trials to creating employee work instructions and associate training. Result of launch activities were 2 (separate programs) customer excellence awards.

Participated in the creation of annual objective and goals for corporate approval, as well as:

Updated customer product specification books.

Determined specific performance standards and wrote specific production procedures.

Designed standard reports of manufacturing shift performance data, including labor efficiencies and overall equipment efficiencies.

Wrote QS/ISO/TS compliant Departmental Procedures, Control Plans and Operator Instructions. Participated in numerous QS/ISO/TS audits and in the resolution of any non-compliant findings. The Bryson City, N.C. facility was the first TS certified plant in the United States.

EXPERIENCE:

HP Pelzer, Thomson, GA

Operations Manager Contract Position 12/15-2/16

Total responsibility for a 3 shift 24 press compression molding operation manufacturing sound deadening insulation to the automotive industry (VW, GM, BMW and Mercedes). Six supervisor direct reports and 150 hourly associates Contract ended.

M-Tek, Inc., Manchester TN

Deputy General Manager Injection Molding/Injection New Launch Coordinator 2005-2015

Total responsibility for Molding KPI’s of customer satisfaction, safety, cost, quality and delivery for a 3 shift Injection Molding, assembly (41 presses, 650 hourly associates) and compression molding headliner operation providing interior trim door panels and headliners to Honda, Nissan and Volkswagen. Directly responsible for root cause analysis for any non-conformance or process deviations and adhering to established process parameters/company standards (SPC). Cross functional liaison with Production Control ( for scheduling and attainment), Engineering (regarding process and tooling issues/changes) and Maintenance (for machine issues and PM scheduling). Held monthly management performance/project reviews. Injection lead role for launch of B12G (Leaf) and P32R (Rogue). Coached and developed subordinates at all levels. Addressed associate performance issues through re-training or counseling. Created yearly operating budget and tracked cost to budgetary goals. Left due to Management DownsTotal responsibility for Molding KPI’s of customer satisfaction, safety, cost, quality and delivery for a 3 shift Injection Molding, assembly (41 presses, 650 hourly associates) and compression molding headliner operation providing interior trim door panels and headliners to Honda, Nissan and Volkswagen. Directly responsible for root cause analysis for any non-conformance or process deviations and adhering to established process parameters/company standards (SPC). Cross functional liaison with Production Control ( for scheduling and attainment), Engineering (regarding process and tooling issues/changes) and Maintenance (for machine issues and PM scheduling). Held monthly management performance/project reviews. Injection lead role for launch of B12G (Leaf) and P32R (Rogue). Coached and developed subordinates at all levels. Addressed associate performance issues through re-training or counseling. Created yearly operating budget and tracked cost to budgetary goals. Left due to Management downsizing Accepted Buy-Out.

Consolidated MetCo-Cashiers Plastics Div., Bryson City, NC

Molding Manager 2001-2004

Responsible for a 3 shift, 37 press Injection Molding and assembly operation supplying interior trim parts to the Heavy Trucking Industry. Molding processes include: straight injection, structural foam and gas assist. Direct reports include: 3 supervisors, 3 foremen, 8 process engineers, quality auditors and 125 hourly personnel.

Left due to layoff.

Oakwood Group-Oakwood Plastics Div., Dearborn, MI

Operations Manager 2000-2001

Management of a 3 shift, 17 press Injection Molding, assembly and thermoforming operation supplying interior trim parts to the automotive industry. This includes the direct reporting of the Manufacturing, Processing, Quality and Materials Departments. Left due to plant closure.

Textron –Westland Operations, Westland MI 1995-2000

Production Manager-Injection Molding, 2000

Production Manager of a 3 shift, 19 press Injection Molding and assembly operation for manufacturing of RS Quarter panels and WJ fascias.

New Product Launch Coordinator, 1999-2000

Part of a Daimler-Chrysler mandated cross-functional team to ensure the successful launch of new injection molding business for the RS and KJ programs. Resumed Production Manager duties in September-2000.

Production Manager, 1995-1999

Hired as Warehouse Manager, promoted to Plant Shift Superintendent, and then to Production Manager. Managed 3 shift, 10 press production of bonded headliners. Was recruited to Oakwood by a previous manager.

Woodbridge Corporation, Romulus, MI

Foam Production/Rim Production Superintendent 1989-1994

Frito-Lay, Inc., Allen Park, MI

Shipping and Receiving Supervisor 1985-1989

Eradico Pest Control, Ferndale, MI

District Supervisor / Account Executive 1978-1985

EDUCATION:

Bachelor of Science in Industrial Psychology (Magna cum Laude) Minor: Mathematics

Michigan State University, East Lansing, MI, 1978

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