Manager Maintenance
Resume:
John F. Long
**** ******* ***** **** ***********@***.***
Home: 615-***-****
Christiana TN 37037 Mobile:
Professional Experience:
ATI Tungsten Materials, 2009 -
Present
LaVergne, TN
Director of Engineering/Maintenance/Continuous Improvement
Reports to the ATI Tungsten Materials President, Primary role: Manage all
Engineering/Maintenance and Continuous Improvement.
Facility Accomplishments:
> Develop working roles for all corporate engineering and maintenance
managers.
> Develop Continuous Improvement and Lean Manufacturing program,
> Develop/Implement maintenance systems and financial systems for all
engineering.
> Develop and managed project management systems for all capital
projects.
> Administer cost savings projects though out all business units
> Develop working role for maintenance
> Establish production tracking system
> Manage two machines shops, tool repair and tool design. (one Nashville
one in Alabama)
> Implementation of OEE World Wide
Financial Accomplishments:
> Implementation of Maintenance Repair and Operation programs for
maintenance cost savings $360,000 first year.
> Implementation of Lean and Continuous Improvement (MU and CU) cost
savings $300,000 first year.
> Reduced engineering cost from $102,000 to $56,000 a month
> Manager all capital request from $10,000 to $100,000,000
> Reduce maintenance work force (Manning & MRO) from $3,000,000.00 down
to $1,200,000.00
Johnson Controls., 1990 - 2008
Cadiz, KY
Plant Manager (Focused Factory)
Reported to the VP of Operations, Primary role was to manage all
Operations/Engineering, along with the shut down and relocation of all
production equipment though out Johnson Controls. Manage plant
engineering, continuous improvement and a maintenance support staff during
a 3-shift 7-day operation.
Facility Accomplishments:
> Managed the launched of two Major Customer's programs, Honda &
Toyota, back to back. Honda required the installation of 11 weld
cells, two stamping presses & four quad cells, Toyota installed
eight weld cells & one stamping presses.
> Developed and planned Project for budget usage and running cost: Honda
$1.2 m, Toyota $900,000
> Developed working role for 4 program managers, 2 tool engineers and 3
ME's
> Manage two plants on layout and material flow.
> Coordinated work force, using millwrights and electrical contracts for
equipment install to meet all safety guidelines for all facilities.
> Coordinate all vendor build, to maintain a strong communication for
equipment standards.
> Set labor standards for production and floor operations
> Coordinate working role for all Maintenance, Tooling and Controls
Engineers for the new equipment install and day-to-day programs.
> Managed electrical and mechanical work though the use of outside
contractors as well as in-house technical support during the
installation phase.
> Sign off on all tooling prints and machines layout during program
launch.
> Attend all run at rates to assure customer tack time, and final
equipment sign off.
> Manage set-up all maintenance and engineering systems though tool crib
manager and plant engineer.
Financial Accomplishments
> Exceeded Plant Improvement Profit Plan Savings Goals for: FY' 06 (by
$1.5), FY' 07 (by $750 k), and FY' 08 (by $892 k).
> Implemented Lean Manufacturing systems,
> Develop a Material Replenishment System to improve machine utilization
plant wide by 15%.
> Manager labor cost from $13,000 a day down to $4,000 a day
> Manager purchase burden from $900,000 a month down to $700,000 a month
> Reduce labor force by 30% in 7 months
> Manage a plant income from a negative $100,000 a month loss to a
positive income of $250,000 a month.
San Antonio, TX
Site Technical Manager/Launch/Continuous Improvement reported
Reported to VP of Operations, Primary role, build two plants, one 500,000
square feet facility and one 200,000 square feet facility. Layout with two
Engineering Managers both plants for electrical, air, water and hydraulic.
Coordinate the equipment purchase with program managers. Manage two plants:
one process center, (injection molding, assembly, welding, over head
systems and foam) and one Just In Time plant (seat assembly, over head
assembly), engineering and a maintenance support staff during a 3-shift 7-
day operation.
Facility Accomplishments:
> Program Manager for a complete build, assemble and start up of both
plants, ($65,000,000) project
> Set-up and manage all maintenance and engineering systems
> Launch in two plants in 7 month: "one" Just In Time Seat, Headliner
and Shipping Systems and "one" Process Center with 2 Foam Lines, 3
Injection Molding machines including a 700 ton, 1500 ton and the first
3000 ton (first in the states),
> Operating 11 weld cells with three stamping presses including a 1000-
ton, 2500 ton and 4000 ton, one headliner press and 11-door assembly
work cells.
> Set labor standard for production and floor operations
> Managed a plant program manager, two-maintenance manager, two
engineering manager, and two continuous improvement managers on a day-
to-day bases as well as during a $65,000,000 launch.
Financial Accomplishments:
> Implemented Lean Visual Management
> Design and implement Material Replenishment Systems to improve machine
utilization for both facilities.
> Manager labor cost to accommodate fluctuation of customer volumes
> Manage purchase burden of $4,000,000 per year
> Reduce labor force by 30% in 7 months
> Manage the plant income from a $100,000 a month loss to a positive
income of $150,000 a month
Missouri
Site Technical/Project Manager
Reported to the Director of Operations, Primary role to build and assemble
the DC plant (distribution plant) and manage all Engineering activities in
two plants (battery assembly and batch and fill operation). Manage two-
plants engineering and a maintenance support staff during a 3-shift 7-day
operation
Significant Accomplishments:
> Set-up and manage all maintenance and engineering systems
> Oversee the build of a DC plant with two Program Mangers, 2 Industrial
Engineers and the maintenance work force. Total Project $110,000,000
> Over see the installs of over 20000 linear feet of conveyor along with
automated picking system.
> Over see the complete build and install of a new battery assembly
system. (New to Johnson Controls)
> Program Manage the design and install of the Mark 7-B battery machine
to increased productivity by 30% and reduce labor 10% ($10,000,000)
project
> Manage both facilities with two Engineering Managers, 2 CI managers
and 2 IT managers.
> Implementation Lean Visual Management
> Manage the plant income for a of $10,000,000 operating budget
> Developed Material Replenishment Systems to improve machine
utilization plant wide
> Build and manage by EQU system
> Manager purchase burden of $15,000 per day
> Reduce labor force by 20% in 1 year
Missouri
Site Technical Manager/Launch/Continuous Improvement
Reported to the Director of Operations, Primary role was to Project manage
the replacement of older equipment. Additional, responsibilities manager
CI department though a CI Manager and four black belts. Manage two-plants
(injection molding and rubber extrusion) engineering and a maintenance
support staff during a 3-shift 7-day operation.
Significant Accomplishments:
> Direct the Implementation of Lean Visual Management systems on all the
production floors.
> Program managed two site builds with 12 machines including injection
molding (ranging from 750 ton to 300-ton presses) and rubber
extrusion. ($65,000,000) project
> Set labor standard for production and floor operations
> Set-up and manage all maintenance and engineering systems
> Programs manage two sites installing 13-injection molding presses
(ranging from 750 ton to 300-ton presses) and 12 rubber extrusion
machines. ($65,000,000) project
> Coordinate all tooling modification though 4 tooling engineers and 12
tool makers
> Manage both facilities though two-plant engineers CI manager, two
maintenance managers.
Regional Engineering Manager/Launch Manager/Continuous Improvement Manager
Reported to the President of Engineering, Primary role, manages all
Engineering Operations activities in the Ford Just in Time business unit.
Additional responsibilities included managing the CI department though a CI
Manager. Manage 12 plant engineers and a maintenance support staff for the
Ford business unit.
Significant Accomplishments:
> Program manage the complete build of the systems (programming, set-up
and production systems)
> Developed Material Replenishment Systems for a 8 hour inventory
systems (material storage systems)
> Design and build a complete plant and shop floor systems (barcode,
shipping and tracking systems)
> Design and manage delivery systems to accommodate customers shipping
requirements.
> Manager purchase burden for 12 plants, $30 million budgeted.
> Set-up and manage all maintenance and engineering systems
> Oversee the build of a 500,000 square foot building, complete with all
needed facilities and assembly system.
> Relocate a complete assembly system in 7 days including all shipping
systems, assembly system, computer systems and shop floor process
> Oversee year model change and install new equipment for 12 Ford and
Assembly plants.
> Support engineering operations for 12 plants though - 12 Engineering
managers, 12 CI Managers, and a corporate staff of three Electrical
Engineers, four Mechanical Engineers and three Industrial Engineers.
> Manager purchase burden for 12 plants of $50,000,000
> Set-up and manage all maintenance and engineering systems
Education:
1982 UNIVERSITY OF TENNESSEE - BSEE
Certified Six-Sigma Green Belt & Black Belt
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