Sales Manufacturing Production

NEIL M. SCHATTIN

*** ****** *** **. ● Muscle Shoals, AL 35661 ● 404-***-**** ●

******@***.***

An experienced, detail-oriented Operations Management Professional with international experience in

optimizing “bottom–line “ results using LEAN, Six Sigma and TQM methodologies on a consistent, focused

and strategically well-planned basis.

SUMMARY OF QUALIFICATIONS

Implemented strategic initiatives to automate manufacturing processes, maximizing productivity while

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decreasing labor content, energy consumption and defective product losses

4 Developed cost-cutting techniques that saved one company over $4.75 Million in annual savings

utilizing Best in Class (Best Practices) systems and production methodologies.

5 Excellent communication skills. Effective Pro-Active Problem Solver and Team Player.

Effective “Change Agent” and “Plant Turnaround Specialist” capable of marshalling company resources

(time, personnel, and equipment) for the maximum benefit of company stakeholders.

7 Highly skilled in providing top management with up to date analysis of improvements planned, expected

benefits (profits, increased outputs, enhanced customer service etc.) and timely tracking of process

metrics (KPI) aligned with company objectives. Provide Key Strategic Planning reports and assessment

of competitors on a Global basis. Enthusiastic and tenacious in dealing with challenging issues.

8 Six –Sigma Certified, specializing in utilization of DFSS, KAIZEN, VOC, 5S, FMEA, KanBan, Quick

Changeover, Cycle Time Reduction and DMAIC methodologies to continuously improve operations,

enhance output and optimize quality. Strong ISO 9001 and TQM experience.

9 Strong Global sourcing negotiator capable of achieving the highest quality products /services at the

lowest price available with minimum operational inventories and maximum inventory turns – possess

extensive JIT and ERP management experience.

10 Possess key presentation skills, capable of distilling complex technical information into simple business

oriented compelling calculations which produce positive results in remarkably short periods of time.

11 Advanced educational background including BS Ceramic Engineering (With Honors) and MBA

Degree- Fox School of Business.

PROFESSIONAL EXPERIENCE

Dal –Italia, LLC

Muskogee, OK

Technical Director 2008-2012

Direct all technical aspects for the largest North American producer of Porcelain Ceramic Tiles using

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one of the most highly automated plants in the world.

Responsible for all ceramic formulations, materials, specification sheets, product transfer, cost-

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containment and reductions for a plant producing over 180 Million square feet (11 acres per day!) of

ceramic porcelain tiles annually.

Reduced energy consumption by over $ 500,000 in the first 10 months of 2008 by improving spray

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drier(s) and kiln performances through innovative improvements in ceramic body slip density and

superior insulation practices. Developed multiple suppliers for specialty chemicals capable of achieving

the overall best energy performance in the company.

Improve process throughput with no sacrifice in quality by over 5%, while steadily reducing production

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costs to unparalleled levels.

Enhanced environmentally “Green Formulations” incorporating recycled glass and other post-industrial

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consumer waste streams.

Developed improved glaze preparation and sourcing techniques to further reduce operational costs by $

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2.5 Million in 2009

Greatly reduced inventory carrying costs by over $ 1.25 Million in glaze area alone.

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Directed the implementation and construction of a new state-of-the-art Glaze Batching System resulting

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in an additional $1.00 Million annual savings using proprietary formulations to meet plant requirements.

This method of preparation enabled the company to meet stringent silica dust control standards which

had previously been elusive.

Guided the implementation of the most advanced and largest under one roof digital inkjet printing

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systems in the USA with the highest percentage volume of any US plant. Developed highly innovative

glazing systems to further reduce costs, improve quality and enhance productivity.

Reduced operational manpower costs by 30 % and simultaneously boosted output by 20 % in the areas

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of body and glaze preparation.

Improved Porcelain achievement status by coordinating kiln, body and processing initiatives to meet

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more stringent requirements. Instituted more comprehensive controls and reporting documents.

Actively maintained liaison with our Italian partners at EmilCeramica and provided technical support to

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our joint venture partner in China.

Maintains continuous awareness of latest ceramic technology on a worldwide basis to promote the

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company’s interests and improve quality, enhance output while simultaneously reducing operational

costs in an environment which champions employee involvement under the safest possible conditions.

Alpha 7 Gypsum, LLC

Atlanta, GA

Technical Director 2007- 2008

Directed all technical and manufacturing aspects for patented process of alpha-hemihydrate plaster from

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a byproduct source of synthetic gypsum. Full EH &S and OSHA responsibilities.

7 Improved percentage utilization of plant resources by 10 % to maximize production while reducing costs

by $25,000 and improving quality

8 Streamlined production process by eliminating “non value-added” steps

9 Reduced energy consumption by optimizing heat treatment process of final product resulting in more

efficient operations and tonnage output through plant operations. Output increased by 12 %.

10 Developed Comprehensive Proprietary Business Plan for licensing and selling future plant sites with

proprietary patented technology

11 Implemented improved production equipment to reduce decibel levels in the plant consistent with noise

abatement policies in force

Colorobbia USA, Inc.

Dallas, TX

National Sales & Technical Director 1999-2004

Managed Technical Operations by providing technical expertise to customers in manufacturing plants

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using specialty chemical and pigment products

Increased sales to major customers by over 15 % resulting in over $325,000 in increased sales by

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streamlining current formulas in various factories

Introduced more efficient coating methods to minimize in-plant waste and reduce waste water streams of

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potentially toxic chemicals in accordance with EPA regulations

Drove company products to ranking as the largest foreign supplier to major accounts by introducing new

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products, optimizing processes and reducing losses in customer plants

Introduced new products into marketplace gaining market share rapidly by over 12 % in a declining

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market environment

Independent Consultant

Florence, AL

Managing Director 1998-1999

Provided operational assistance to clients in process improvements and cost reductions

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Developed new cost-effective body formulations to save clients over $1 Million per year

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Improved yields in ongoing manufacturing processes and directed improvements in process flow

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technology to further reduce costs enhance outputs and streamline production lines through the concept

of LEAN Manufacturing. Eliminated non value-added steps in manufacturing processes

Provided insights into plant layout designed for maximum productivity, minimum energy costs and

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reduced waste water streams for environmental purposes

Monarch Tile, Inc.

Florence, AL

Vice President-Operations 1996-1998

Managed operations, Budget Expenditures (P&L) and Capital Equipment purchases for 3 fully

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unionized plants totaling over 350 employees. Improved safety culture by emphasizing safe work

practices

Designed and constructed new $18 Million production facility, introducing highly automated, foreign

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sourced equipment and production methodologies

Reduced work-in-process by 80 % which resulted in $4.75 Million in annual savings

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Reduced production costs in areas of raw materials, labor expense, energy consumption and streamlined

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material flow achieving a 50 % cost reduction that resulted in $7.5 Million annual in plant savings

Achieved lowest cost producer in USA status by aggressively reducing costs and enhancing productivity

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with no sacrifice in product quality

Company literally went from “worst to first” in plant production costs reduction in just over 1 year

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Enhanced performance of new plant operations by over 25 % from budgeted expectations after my

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arrival

Developed and improved water treatment system for the plant to meet more stringent EPA water

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regulations

TileCera, Inc. (Division of SIAM Cement Group)

Clarksville,

TN

Technical Director & Asst. Plant Manager 1991-1995

11 Developed and implemented all manufacturing operations and provided technical engineering support

for a $60 Million state-of-the art plant from startup to full production in a rapid time frame

Managed International Technical Teams (Italy & Thailand) and launched new product lines to lift the

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corporation from obscurity into one of the nation’s most prestigious manufacturers

Directed achievement of ISO 9001 certification within a 10 month period, by training personnel in the

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areas of SPC, TQM and process variance techniques to insure optimum production quality and elevated

customer service levels. Championed Reliability Excellence processes at the manufacturing site

Entrusted with establishing the initial Purchasing Department for the company-was instrumental in

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securing all raw materials at the lowest possible cost consistent with the highest quality standards. Also

organized all transportation into the plant on both a domestic and Global sourcing basis.

Spearheaded the implementation of the “BPICS Enterprise Planning System” for all manufacturing

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operations and maintained updates BOM on all production products

Developed new products that generated in excess of $12 Million in sales for the company

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Developed the proprietary ISO Press System for the first production of large format ceramic tiles in the

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USA prior to all other competitors. Reduced the size variation in our warehousing system.

Increased output by optimizing production process over 20 %, resulting in additional saleable products

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of $7 Million

Developed new formulations consistent with recently enacted environmental rules which enabled the

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company to avoid investments of over $4.35 Million in emissions abatement equipment

$500K annual savings by instituting a comprehensive recycling program for previously discarded

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materials and reducing environmental recordkeeping

Designed waste water flow system to be 100% self contained – no waste water was ever discharged

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from plant site- this allowed the company to avoid expensive water treatment processing equipment and

chemicals as well as extensive state and federally mandated reporting requirements

American Olean Tile Co., Inc.

Lansdale, PA

Director Process Research 1978-1991

Directed research efforts for $200 Million organization; supervised staff of over 15 engineers,

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technicians and designers. Main plant consisted of 12 kilns for tile production plus another kiln for

refractory production.

Planned, implemented and controlled a $21 Million investment to modernize the plant for ceramic wall

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tiles production with 8 new roller kilns in less than 20 % of the existing plant space.

Research efforts encompassed all 8 plants in the Groups manufacturing sector from coast to coast

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Created new technology to incorporate the latest advances in JIT manufacturing capability and

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versatility while optimizing the cost of production to the lowest level in the history of the company

Reduced overall production costs by 35 % resulting in over $5 Million in annual savings in one plant

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alone

Eliminated negative variances by initiating Continuous Process Improvement and cost reductions as

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opportunities arose

Documented projects resulted in minimum savings of $150-200K per year in ongoing manufacturing

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costs

Developed special “Porcelain Tunnel Tile” products for vehicular travel in tunnels in Baltimore, MD,

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specifically the Fort McHenry Tunnel.

Pioneered research efforts with engineers from the former Soviet Union concerning newly created

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thermal energy products, capable of being fired in cycles as fast as 22 minutes

Ferro Corporation Cleveland, OH

Ceramic Engineer 1973; 1976-1978

Improved productivity and reduced costs by designing new processes and glaze and frit formulations

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Developed specialty formulations used by clients to replace scarce raw materials due to ongoing war

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demands with no sacrifice in quality

Assisted clients with development of specialty products to gain increased market share vis-à-vis their

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competitors

United States Army

Fort Knox, KY

Captain 1974-1975

Responsible for over 100 men in my first Military assignment in excess of $ 10 Million worth of

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equipment and supplies

Developed specialties in Chemical, Biological and Radiological warfare techniques and

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counterinsurgency methodologies

Maintained proficiency by attending advanced Military schooling and was also assigned to Radiological

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teams in the event of incidents here in continental USA

Organized the preparation, loading and shipment of thousands of tons of materiel to overseas theaters of

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operation to support ongoing combat operations

EDUCATION

BS, Ceramic Engineering (With Honors): Rutgers-The State University

MBA, Management & Organization: Temple University

SIX SIGMA- Certified

TECHNICAL SKILLS & AWARDS

Computer Skills: Microsoft Office, Project, Outlook, PowerPoint and Access, MINITAB (Six Sigma), ERP,

BPICS, EVOLVER Optimization Software and Palisade NEURAL NETWORK Business Predictive

Software, Dale Carnegie Awards- Human Relations, Breakthrough & Crashing Through

Fellow: American Ceramic Society

Languages: Fluent in Italian, Proficient in Spanish, German, and French

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