Operations Manager
Resume:
Gerald Ross
Loveland, Ohio 45140
Email: See contact information field of website
Objective
To obtain a professional position that will utilize my 22 years of experience in operations management, engineering and quality.
Professional Summary
Strong and decisive operations leader with excellent analytical, organizational, team building and planning skills with a proven record of operational excellence. Effective technical and communication abilities. Extensive aerospace and carbon/carbon composite material experience, with demonstrated success in lean implementation, cost reduction and improved quality. Core knowledge and skill areas include; Operations Management, Engineering Management, Lean Manufacturing Practices, Project Management, Value Stream Management, Plant Maintenance/Equipment Reliability and Quality Assurance Management.
Experience
Harris Products Group, Mason, Ohio (April 2008-June 2009)
Engineering Manager
Manager of all engineering, R&D, CapEX projects and master data. Led continuous improvement efforts to reduce lead time, improve safety, improve quality and reduce waste. Span of control included 6 engineers, 2 master data specialists and 3 engineering technicians. Key accomplishments include:
• Completion of 4 Six Sigma projects for a total company savings of $350,000 with increased plant capacity
• Developed a new shaved 5356 aluminum welding wire that reduced smoke and porosity by 50% from the original aluminum product.
• Managed capital expenditure budget of $2,000,000 and developed a plan of execution
• Completion of 145 total plant projects for operations, quality, maintenance and safety
• Completion of 6 capital expenditure projects
• Implemented OEE in manufacturing processes to improve plant efficiencies
• Value stream mapped 2 production material groups and reduced inventory levels by $3,600,000 and raising inventory turns from 2.3 to 4.4.
Messier-Bugatti USA, Walton, Kentucky 1999-2008
Operations Manager (2003-2008)
Promoted to overall management and technical leadership of all carbon/carbon aircraft brake production teams and its related equipment, facilities, and maintenance. Lead continuous improvement efforts to reduce lead time, improve safety, improve quality and reduce waste. Span of control includes 9 manufacturing teams consisting of 10 direct reports and 75 indirect reports and managing a 20 million dollar budget. Key accomplishments include:
• Successful implementation of continuous improvement programs (lean, kaizen, standardized work, value stream mapping and 5S) creating a lean culture and being the northern Kentucky benchmark for lean manufacturing
• Successful implementation of Total Productive Maintenance (TPM) program leading to world class equipment effectiveness and being a leader in equipment reliability
• Integration of predictive maintenance technologies including vibration analysis, ultrasonic thickness testing, ultrasonic airborne testing, oil analysis and thermal imaging.
• Established long term strategic operations and maintenance plan
• OSHA incident rate in the very good range
• Trained all production and maintenance teams on root cause analysis problem solving
• Managed operations through multiple plant expansions and process changes, which included increasing production levels by 250%
• Met and exceeded quality and customer satisfaction goals despite running operations at 99% utilization of the constraint
• Met and exceeded all financial targets determined by the business plan, including inventory, revenues and operating profit
• Reduced inventory investment by 25% in 2 years using a pull system
• Cut the costs of equipment repair and maintenance by 50% over 3 year time line
Quality Engineer/Lab Manager (1999-2003)
Joined MB-USA as part of a technology transfer team that went to a sister company in France to bring back the carbon/carbon composite technology to the United States. Purchased, started up and qualified all laboratory equipment during plant startup. Span of control included 3 laboratory technicians and 2 quality inspectors. Key Accomplishments include:
• Project manager for the qualification of the Quality laboratory during the start-up of the company. This consisted of working with a 1 million dollar budget to plan the lab layout, order the test equipment, qualifying the equipment and the hiring of lab personnel.
• Monitored process capabilities through statistical analysis (Cpk, linear regression, ANOVA)
• Led continuous improvement teams using six sigma quality tools to eliminate nonconformance and process disruptions
• Facilitated Material Review Board meetings to accurately determine root cause of process problems
• Create a 6-month/year end Quality report to give updates on material and process capabilities, process and material nonconformance, corrective action status and recommendations for improvements
• Performed internal audits of all manufacturing processes according to ISO 9001:2000 and AS9100 standards
• Taught Engineering statistics and Design of Experiment (DoE) to process engineers
Materials Behavior Research Corporation, Loveland, Ohio 1989-1999
Test Engineer/Lab Manager
Joined MBRC after graduating from Xavier University to lead and manage the test laboratory and work with aerospace engineers on defining test programs, test design and data analysis. Span of control included 5 lab technicians. Key Accomplishments include:
Managed day to day operations of the test laboratory, assigning work load and prioritization of test programs
Develop test programs for aerospace engineers to establish fatigue life curves for aerospace materials
Part of development team to obtain SBIR programs for MRBC. Developed behavior of Ti6-4/SCS-6 composite material for U.S. military as part of a SBIR program
Develop new R&D test methods on materials for aerospace applications and medical device testing
Working knowledge of ASTM standards for material testing applications
Education
Master of Science in Technology Management (Quality Assurance) from Northern Kentucky University
Bachelor of Science in Applied Physics/Engineering from Xavier University
Training/Skills
Total Productive Maintenance training, University of Dayton
Lean Leadership Certification (TPS), University of Kentucky Lean Leadership Institute
Lean Manufacturing training, Gateway Technical College
Leadership Effectiveness Program, Effective Dimensions International
Six Sigma Red (Green) belt training, Lincoln Electric Six Sigma Program
Proficient in all Microsoft Windows based software, Minitab and SPSS statistical software
Working on obtaining APICS certification through training classes offered at MB-USA
Safety Training Observation Program, internal training through Dupont safety program
Finance and Accounting for Non-Financial Managers, American Management Association
Lincoln Electric Six Sigma certification training
Achievements
Certified Quality Manager (CQM) certification from the American Society of Quality
ISO 9001:2000 certified internal auditor, American Society of Quality
Messier Bugatti creativity award winner for most creative idea in the production field
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