Plant Manager

Frederick C. Winner

**** ******* **** ***********, ** 28590 252-***-**** ****.******@*****.***

PROFESSIONAL PROFILE

Accomplished food manufacturing executive with extensive experience building, developing, and leading

diverse teams to improve operational efficiencies, enhance customer relationships, and increase

profitability. Proven ability to lead major start-up initiatives through focused planning and execution, and

utilizing Lean Manufacturing techniques. Possesses HACCP Manager Certification and SQF Practitioner

Certification, and have successfully implemented Food Safety Modernization Act policies and practices.

CAREER HIGHLIGHTS

• Expanded production tonnage by 40% by successfully installing and placing into production two

production lines that enabled co-packed products to be manufactured in-house. This initiative

provided annual savings of $2M, and reduced consumer complaints by 50%.

• Reduced material variances by 75% in a high speed dough operation by introducing Standardized

Work, and Root Cause Problem Solving techniques. This resulted in savings of $.975M annually.

• Spearheaded major initiatives to reorganize the company’s largest baking facility in order to drive

compliance with the new FSMA. This involved 60% of the facility 9 Value Streams in a six

month period, and required $30M in capital expenditures. Met or exceeded all KPI’s during this

time.

• Led teams in the construction and successful start-ups of two plants that were in excess of

350,000 square feet.

PROFESSIONAL EXPERIENCE

SARA LEE CORPORATION- Downers Grove, IL 2001-

Present

Plant Director- Tarboro, NC 2010-Present

Responsible for 750 non-union employees in the company’s largest frozen baking plant. This 400,000

square foot facility comprises 18 make-up and 22 packaging lines. Tasked with P&L, planning,

manufacturing, maintenance, quality and environmental system management. Facility produces 140m

pounds of sweet goods and sandwich carriers comprised of 240 unique SKU’s, and has a total annual

spend of $160M.

• Developed and managed teams that started up high speed lines for the production of croissant

and biscuit sandwich carriers, which eliminated co-packing costs of $2M annually.

• Developed new process for dough production that will save $1.4M annually

• Achieved $4.1M in cost savings by applying Lean Manufacturing techniques primarily through

Value Stream Mapping, Root Cause Problem Solving, and Standardized Work Methods.

• Led implementation of SAP system to focus on and reduce material variances.

Plant Director- Greenville, SC 2006-2010

Had responsibility for the second largest volume producing plant in the Food Service/ Diversified

Products Division. This facility produced 150+M pounds of frozen dough and bagels for two key

National Restaurant accounts.

• Delivered savings of $5.9M vs. a target of $2.5M by reducing material losses and reducing labor

costs.

• Expanded production in bagels by 27% by organizing a CI Workshop with customer designated

teams.

• Achieved Plant of the Year designation by Sara Lee Corporate.

• Achieved designation as a model plant for employee engagement.

Director of Operations- Tarboro, NC 2001-2006

Had responsibility for planning, scheduling, material management, manufacturing, and maintenance of a

facility employing 1300 non-union employees producing frozen sweet goods.

• Co-sponsor of Lean Manufacturing initiative. In a five year period, activities reduced costs by

$20M through the application of Root Cause Problem Solving, 5S, Line Balancing, and Value

Stream Mapping.

• Facilitated R&D efforts to successfully launch numerous new items and re-formulate existing

items for nutritional requirements and cost savings.

• Developed and implemented initiatives in organizational development, food safety, and new

product development/ commercialization.

INDYBAKE PRODUCTS – Seelyville, IN 1995-

2001

Chief Operations Officer

Reported to the owner of a privately held contract baking concern, was responsible for an existing

facility and the start-up of a new acquisition. My duties included sourcing potential customers, facility

upgrades, equipment selection and installation, process development, and staff/ workforce development.

• Developed a process for a new customer that increased productive throughput by 600% over

existing methods.

• Partnered with Conagra, Pepperidge Farm, Kellogg, and Kraft to develop processes for the co-

packing of existing items, or the introduction of new items.

CPC INTERNATIONAL- Chicago, IL 1994-

1995

Production Manager

Was responsible for all production activities at Entenmann’s second largest Danish and sweet goods

plant which serviced fourteen states with fresh product, and supplied five international markets with

freeze thaw items. Facility employed 500 union employees in a seven day continuous shift operation.

• Led an initiative to increase sales by 1M units in a 3 month period by schedule alignments that

enabled increased up time.

• Reduced material losses by 50% by instituting improved ingredient tracking and minimizing

spoilage of perishables.

CONSOLIDATED BISCUIT CORPORATION- McComb, OH

1990-1994

Corporate Planning Director-McComb, Oh 1993-1994

Promoted to a staff position of a $375M manufacturer of baked and snack foods. Developed and

implemented a corporate strategic planning process, and handled account management for their largest

private label customer. Developed a multi-plant manufacturing plan which resulted in synergies across

the supply chain. As a result of these efforts, the oldest plant in the system was closed.

Vice President/ General Manager- Pikeville, KY 1990-

1993

Responsible for the construction and start-up of a new 325,000 square foot baking facility employing

400 non-union employees. The plant produced 45M pounds of baked goods for contract customers and

the ice cream products division which entailed 360 SKU’s. Duties included staff recruitment and

training, equipment acquisition and layout, and development and marketing of new products.

• Facility was completed on time and budget, and reached profitability in its second year of

operation.

• Developed and implemented a baking science and technology class to develop the workforce.

• Successfully started production of items for an expansion into ice cream products.

MRS. ALISON’S COOKIES- Plant City, FL 1988-

1990

Vice-President/ General Manager

Reported directly to the owner of a baking plant involved in cookie production. Responsible for all P&L

activities.

• Initiated a DSD program for the state of Florida that serviced grocery outlets and prisons.

• Reduced scrap rates 50% by introducing line balancing and level scheduling.

• Developed eleven new products for three separate sales channels.

• Achieved first year of profitability at this location.

BAHLSEN, INC.- Cary, NC 1981-1988

Assistant Director of Operations 1983-1988

Had responsibility for all manufacturing and related activities of a 500 union employee snack food

bakery. Recruited and trained a new management team, and achieved major achievements in quality,

service, and productivity. Directed R&D efforts to develop new products for contract manufacturing.

• Successfully negotiated two, three year labor contracts that contained labor costs.

• Constructed a new 350,000 square foot facility while maintaining responsibility for an existing

facility.

• Achieved $6M positive to budget by increasing productivity and reducing material variances.

Production Manager 1981-1983

• Successfully developed new products and packaging that increased sales to new customers by

32%, and expanded sales to an existing customer from $1M to $14M.

• Re-designed plant layout and equipment to drive efficiencies that resulted in a $3M positive

impact to budget

PEPPERIDGE FARM- Downingtown, PA 1978-1981

Product Technologist 1980-1981

Was selected by corporate to fulfill a newly created position unique to the company’s culture. Was

tasked to create and then to introduce a new line of savory puff pastry entrees to open new markets for

sales. Worked with engineering, product technology, and manufacturing at both the corporate and plant

level to successfully launch this product, which resulted in an increase of 20% in production for this

division.

Shift Manager 1978-1980

Responsible for production activities in the biscuit/cracker and bread/roll/ English muffin operations.

Duties included personnel scheduling, facilitation of R&D activities, and cost savings projects.

EDUCATION AND PROFESSIONAL DEVELOPMENT

BA-ECONOMICS, LYCOMING COLLEGE WILLIAMSPORT, PA

AIB- RESIDENT COURSE MANHATTAN, KANSAS

YOUNG EXECUTIVES INSTITUTE UNC, CHAPEL HILL, NC

HACCP MANAGER CERTIFICATION CHARLOTTE, NC

SQF PRACTIONER CERTIFICATION CHICAGO, IL

BOARD MEMBER- CHAMBER OF COMMERCE TARBORO, NC

BOARD MEMBER- UNITED WAY TARBORO, NC

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