Manager Engineer

***** ****** ****** *** ****: 317-***-****

Noblesville, IN 46060 Mobile: 317-***-****

Email: ab2yhh@r.postjobfree.com www.linkedin.com/in/powersdavid

DAVID R. POWERS

Senior Manufacturing Operations Leader

Experienced, high-energy, plant manager with a strong record of achievement

in manufacturing management of union and non-union workforces in the

Pharmaceutical (cGMP), Consumer Electronics, and Automotive Industries.

Extensive background in manufacturing technologies, including assembly,

batch and continuous processing, extrusion and milling processes.

Possessing unique blend of skills in mechanical engineering, lean

manufacturing, continuous improvement, leadership and cross-functional team

building. Recognized for ability to recruit, develop and motivate high-

potential leaders and contributors. A proud, decorated US Navy veteran who

served in the Desert Storm (Kuwait) campaign.

CORE COMPETENCIES

Operations Management Cost Reduction Strategic and Capital

cGMP/HAACP/SQF Compliance Planning

Full P&L Program Management

Responsibilities Organizational Leadership Supply Chain Management

Lean Manufacturing S&OP (Sales & Operations

Continuous Team Development Planning)

Improvement

PROFESSIONAL EXPERIENCE

RED GOLD, Orestes, IN. A family owned and operated tomato processing

company. 2012-2013

Production Manager

Managed plant operations in a 250-650 employee cGMP/HAACP manufacturing

facility. Guided plant operations in the areas of processing and packaging

and serves as the "manager in charge" in the absence of the plant manager.

Leads the communications, coordination and commitment of production

efficiencies, customer satisfaction and operational goals.

Responsible for Capital/Expense Budgeting, SQF Level 3 Attainment,

Continuous Improvement and Employee Growth.

COLORCON, Inc., Indianapolis, IN. A $600MM, world-leading manufacturer of

pharmaceutical 2005-2011 ingredients and coatings. The

Indianapolis site manufactures the Surelease and Starch 1500 product

families

Site Manager 2006-2011

Managed all aspects of 53-employee cGMP/HAACP manufacturing facilities for

solid dosage pharmaceutical excipients, film coatings and food ingredients.

Activities included production, quality, safety, capital planning,

procurement, maintenance, workforce development, and

storage/handling/distribution of Colorcon and Dow excipient products.

. Led corporate team to obtain Colorcon's first North American ISO9001:2008

site certification

. Developed and spearheaded programs for Lean Manufacturing, Statistical

Process Control (SPC), and Operational Excellence, later adopted company-

wide. Implemented 5S, Visual Management, Kaizen, Kanban, single-minute

exchange of dies (SMED), corrective and preventative action (CAPA/RCA)

analysis, and failure modes and effects analysis (FMEA).

. Applied Lean and Six Sigma methodologies to increase first time right

(FTR) quality by 12% and inventory turns by 120%, while reducing process

variability by 80% and scrap by $500k/yr.

. Increased manufacturing capacity by >200% to meet dramatic increases in

demand, through debottlenecking of existing lines and refurbishing of a

mothballed line for $300k, avoiding need for a $4MM capital expansion.

. Implemented systems, procedures and training to increase profitability by

22% through a 38% reduction in overhead expenses and a 50% reduction in

direct manufacturing costs (which offset 30% increase in raw material

costs.)

. Developed flexible workforce enabling employees to flow to the work,

meeting sales growth with no increase in headcount.

. Led behavior-based safety programs, reducing recordable incidents by 70%

in 4 years, with 0 incidents in 2010.

. Implemented key performance metrics including FTR and Overall Equipment

Effectiveness (OEE), which were later adopted company-wide, resulting in

greater employee engagement and focus on business results.

. Coordinated $1.5 MM project to bring site into compliance with OSHA

combustible dust safety emphasis program.

Maintenance & Engineering Manager 2005-2006

Managed activities related to Engineering, Maintenance, Production, Capital

Projects, Continuous Improvement, Workforce Development, Safety, Security,

Budgets, and Local IT.

. Established maintenance systems, process modifications, and procedural

changes to achieve the following improvements within 12 months: Uptime

52% to 88%, Yield 52% to 92%, Quality 94% to 97% FTR, OEE 24% to 72%

. Developed skill sets of Site Support Engineer and maintenance personnel

in the areas of equipment repair and maintenance techniques plus root

cause analysis (RCA), FMEA, and reliability centered maintenance (RCM)

. Initiated and managed safety improvement programs: contractor safety,

static hazards control, Arc Flash, First Responder (CPR, AED, 1st Aid),

and Lock-out Tag-out (LOTO)

TECHNOLOGY PERFORMANCE GROUP (Eli Lilly & Company), Indianapolis IN.

2003-2005

A $50MM service provider in asset management, professional engineering and

maintenance, contracted by Eli Lilly. Emphasis on Right Information

(Maintenance/MRO strategies) using Reliability Centered Maintenance (RCMII)

and Maximo (CMMS).

System Support Team Lead

Performed diverse role leading capital projects and process improvements

for client. Responsibilities included FMEA, development of corporate

policies, re-engineering of process flows, Materials Management for

maintenance, repair and operations (MRO) plus maintenance database

administration (DBA).

. Performed and validated FMEAs for new equipment. Conceived Right

Information process flow improvements, preventative maintenance (PM) and

equipment layup procedures. Managed work and resource planning.

. Led skill set assessment and individual training plan/mentoring program

for 30 personnel in RCM, MRO and DBA.

. Created Corporate Safety Policy, providing management and positioning pre-

qualified/preferred status with customers.

. Supported Materials Management with bill of materials (BOM) creation,

Maximo Item Change Request System (MICRS) utilization, and data

validation/tracking for 6000+ items.

. Performed all major DBA development and maintenance functions for two

major projects (>$100MM combined) using Maximo and the Maintenance And

Validation Right Information Kit (MAVRIK).

DELCO REMY AMERICA, Anderson, IN. A $1B manufacturer/remanufacturer of

alternators, starters 2001-2002 and hybrid motors for light-duty and

heavy-duty equipment markets.

Technical Manager

Managed 56-person department covering engineering, maintenance, customer

service and facilities for three assembly plants. Responsible for

engineering/maintenance team development, manufacturing forward plan,

capital projects and spending.

. Led engineering teams for process/quality improvements to minimize cost

and maximize capabilities using OEE, Earned Value Effectiveness (SPI,

CPI), and Autonomous Maintenance.

. Managed maintenance teams for reliability and continuous improvement

using Preventive Maintenance (CMMS) and visual management. Restructured

engineer/maintenance staffing to give 24% reduction in personnel costs.

. Improved equipment preventative maintenance completion rates by 73%

through optimized planning.

. Created visual management systems for performance optimization.

Restructured plant layouts giving a $120k/yr fixed cost reduction.

Implemented Shop Floor Excellence, Standard Work and 5S to comply with

Lean and QS9000 standards.

. Reduced maintenance costs by $25k/mo. by coordinating first-tier

Crib/Kanban/Depot supplier changes. Established 40/60 repair vs.

improvement spending policy.

THOMSON Consumer Electronics Inc., Indianapolis IN. Thomson is now part of

Technicolor SA, 1995-2000

A $4B French manufacturer of consumer electronics products, specializing in

televisions.

Lean Manufacturing Leader 1999 - 2000

Manager of Maintenance Systems 1998 - 1999

Reliability Engineer, Maintenance Coordinator, Capital Project Engineer

1997 - 1998

Thomson Technical Leadership Program 1995 - 1997

. Maintenance Supervisor, Equipment Design Engineer, Quality Engineer, and

Materials Engineer

EDUCATION

Bachelor of Science in Mechanical Engineering Purdue University,

Indianapolis, IN. (1995)

SOFTWARE

Oracle R11.0 Production, Maximo, Maintimizer, RCM Turbo, Autocad, Visio, MS

Project, Microsoft Office Suite.

ACTIVITIES/HONORS

American Chemical Desert Storm Navy Achievement Meritorious Unit

Society Medal Medal Commendation Medal

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