Post Job Free

Resume

Sign in

Manager Quality

Location:
Lebanon, OH
Posted:
October 22, 2012

Contact this candidate

Resume:

Peter S Gibson

*** ****** ***** ****

Lebanon. OH 45036

Cell 513-***-****

ab8wv2@r.postjobfree.com

General Director of Manufacturing

DYNAMIC, GOAL-ORIENTED MANUFACTURING MANAGER with more than 20 years of

experience who consistently strives to optimize operations, reduce overall

cost, and improves service quality while strengthening bottom-line

profitability. Possess thorough understanding of plant operations, based on

actual hands-on-experience, and ability to adapt to new and different

environments. Core leadership qualifications include:

* Operations Management * Inventory Control

* Staff Training, Scheduling & Development * Workflow Optimization

* Floor Plan Optimization * Supplier/Vendor Relations

* Team Building, Coaching & Mentoring * Quality Assurance

* Conflict Resolution * Safety Development

Professional Experience

Amantea Non-Woven, Cincinnati, OH 2010-

Present

Director of Manufacturing/Plant/Quality Manager

Report directly to the CEO, running the day to day operations with

providing an acquisition layer (AQL) material to Proctor & Gamble (P&G) for

use in its brand name of Pampers Diapers. Directly responsible for 57 non

union hourly employees along with directing 10 salaried employees for a

hygienic manufacturing facility.

Select Accomplishments...

. In September (2010) upon my arrival to Amantea I was directed to

turn plant operations around within 3 months or P&G wouldn't

renew existing contract which would result in closure of

facility. Prior to the end of 2010 P&G extended contract for

Amantea Nonwovens by 2 years (through 2012) due to immediate

continuous improvement initiatives with documented positive

change in Safety, Quality and Performance Programs.

o Amantea had a quality reject rate (prior 2010) of 1.23

along with 18 QI's (Quality Incidents) resulting in a

ranking of 14 out of 14 in P&G suppliers. Since September

2010 we've had a Quality Reject Rate of 0.06 along with 4

QI's (over the last two years) with a P&G supplier ranking

of 3 out of 14.

. Prior to 2010, Amantea had 5 recordable accidents which since my

arrival Amantea has had 0 recordables through 2012.

. In 2011 successfully completed a 30% increase in speed

qualification through P&G guidelines (from 77.6 mpm to 110 mpm).

. Significantly Improved Bottom Line Results in each of the last

two years (from 2010 through 2012) in operation's by 125%.

. Qualified installation of an additional roller on line (Winder)

to widen web by 4.5 cm (resulting in reducing overall scrap by

2%) improving our process capability by 6.2%.

Peter S Gibson page 2

. Qualified start/stop inspection of material through P&G which

increased overall process capability by reducing scrap by

600,000 sqm (10 % of annual scrap rate).

. Qualified 2 additional pigments (new products) for secondary

supplier per demand of customer.

. Qualified reduction of energy which financially reduced our

annual cost by $360,000 along with a reduction of required

maintenance by 25%.

. In 2011 reduced the cost of labor by 12.5%.

. Prior to 2010 P&G performed a QAKE Audit (P&G's Quality

Assurance 19 Key Elements) where the facility scored a 6.

o Within 6 months of my initial arrival we went from a 6 to a

50 in 2011 to a 73 in 2012.

. Designed and implemented an Electrical Training Program through

Cincinnati State that was customized to our equipment with a

100% success rate of completion of Amantea's Maintenance

personnel and key members of the Leadership Team (qty of 12 team

members).

. In 2012 successfully completed a new fiber qualification through

P&G guidelines to improve overall performance at a reduced cost

of 6%.

. In 2012 initiated with success completion through

facilitation/implementation of Black Belt Project: Scrap

Reduction of a 24.4% improvement.

. Developed/implemented a Computerized Maintenance Management

System (CMMS) at a minimal cost for Predictive/Preventive

Maintenance Program.

. Implemented a Sequel (SQL) database to develop/implement

barcode/quality system tracking program to reduce inventory

costs/improve efficiency through standardization of work

practices/minimize risk to customer.

Graphic Packaging International, Marion, OH

2008-2010

Finishing/Process Improvement Manager/Lean Six Sigma Certified Black Belt

Report directly to the Site Manager, completing a minimal of 2 corporate

approved Six Sigma Projects per year. I'm directly responsible for managing

145 non union hourly employees along with directing 7 shift leaders for a

major folding carton leader.

Select Accomplishments...

. Transitioned a Work Cell from Middletown, OH to Marion, OH

within budget where I facilitated kaizen events in the following

areas: 5s, Single Minute Exchange of Dies (SMED), Total

Productive Maintenance (TPM) and Standard Work.

. An active member in the designated Integration Team in closing

the Middletown facility in 2008.

. Improved efficiency in the transition of the Work Cell within

the first year at Marion by 20% from its previous location at

Middletown, OH.

. Facilitated Project Team at Marion, OH in implementation of

forming project where we actively formed a new department in a

designated location within the facility installing 13 new

forming machines.

. Part of Improvement Team where we redesigned and reengineered

key sections of the Former's where we improved overall

efficiency by 22% at a minimal cost of $4500 per machine.

. Established and implemented an extensive supervisory program in

improving the overall net effective output of equipment (NEO

which is the total produced cartons divided by the total time).

. Initiated cost saving programs for the raw materials within the

department where we saved an estimated 10% in 2009 and an

additional 8% in 2010.

Peter S Gibson page 3

Altivity/Graphic Packaging International, Middletown, OH

June 2006-2008

Lean/Process Improvement/Production/Maintenance/Environmental Manager

Report directly to the General Manager, implementing new ideas based on

continuously improving the daily flow of operations at the facility. I'm

directly responsible for managing 137 union hourly employees along with

directing 4 shift leaders for a major food packaging manufacturing facility

which is the largest non-beverage container board company in North America.

Select Accomplishments...

. Within the first six months of employment was able to improve

and sustain total production by 20%.

. Was an active member on a 5S/SMED project team at the Muncie

facility where as a group helped reduce total changeover time by

42%.

. Reduced the overall headcount at the facility by 25% by

implementing change within the processes along with the

procedures to help improve overall efficiency at the plant.

. Conducted monthly safety meetings with the employees, which

helped improve reducing the number of accidents within a

calendar year by 400%.

. Implemented an effective maintenance program that improved plant

wide efficiency by 30% within six months.

. Facilitated a project team that reduced Lithographic Make-Ready

time from 2 hours to 1 hours.

. Planned and controlled a capital project that totaled $200,000

in cost that involved the rebuilding of a cutting press that

increased production from 5,000 sheets per hour to 7,700 sheets

per hour.

. Implemented a facility maintenance plan towards saving the

company on utility expenses by more than $100,000 per year.

. Conducted a Standard Work project that implemented

improvements/tasks in order to improve efficiency by 43% per

day.

. Planned and controlled a capital project that totaled $87,000 in cost

that improved the overall efficiency of a Work Cell by 30%

within a two week period.

Da-Lite Screen Company, Inc., Blue Ash, OH

1999-2006

Plant Manager

Reported directly to the Vice-President, overseeing the daily operations

with accountability for manufacturing, quality, engineering, new product

development, production control, tooling, safety, and regulatory affairs of

more than $100 million annual revenue of a non-union chemical manufacturing

company which produces projection screens using a coating process.

Select Accomplishments...

. Implemented programs for cost reductions that totaled more than

$5 million on average per year.

. Improved shipments on average of more than 20% per year.

. Implemented both a lean manufacturing process and type of

thinking amongst my employees at the facility.

. Implemented a Safety Program that helped promote employees

awareness of their immediate surroundings.

. Assisted in designing and developing new procedures for our

product lines. By streamlining the process, efficiency was

raised by 30%.

Peter S Gibson page 4

. Assisted in developing new machinery for our flexible department

which increased our overall production by 300%.

Sun Chemical, Cincinnati, OH

1997-1999

Production Supervisor

Managed 36 union hourly employees in a major chemical manufacturing company

which produces both dry color and pigments.

Select Accomplishments...

. Responsible for the production of $1 million of pigment on

average per day.

. Improved line efficiency by 34%.

. Coordinated company efforts with a major customer to develop an

effective campaign to improve packaging for two of our finished

products.

. Created and implemented a successful safety program.

Springdale Ice Cream & Beverage, Cincinnati, OH

1996-1997

Production, Maintenance, and Sanitation Supervisor

Managed 53 union hourly employees in a major dairy and beverage

manufacturing company.

Select Accomplishments...

. Created and implemented a Master Sanitation Schedule for the

daily safety and cleaning of the facility.

. Reduced chemical usage and chemical cost by 30% over a period of

6 months.

. Improved the efficiency of the Ice Cream Department by 20%.

. Attended a two-week course on Ice Cream Manufacturing at Penn

State University in January of 1997.

Edy's Grand Ice Cream, Fort Wayne, IN 1992-

1996

Coordinator and Cost Administrator

Handled day-to-day activities including team staffing, attaining downtime

leadership and schedule accordingly, inventorying and ordering team

supplies, scheduling and facilitating team, problem solving and initiating

goal-reaching programs. Also, responsible for cost, quality and production

control.

Select Accomplishments...

. Established the transformation of the production lines to a

continuous-run operation with minimum loss to the company.

. Established an interview program that was responsible for

obtaining high quality potential job applicants for future

employment.

. Saved the company over $300,000 after conducting a study on

defective packaging from one of our vendors.

Peter S Gibson page 5

Educational Background

PURDUE UNIVERSITY - West Lafayette, IN - 5.89 on 6.0 Scale (GPA)

1988-1992

Bachelor of Science, Management

. Distinguished student 1991 & 1992

. Sigma Phi Epsilon Fraternity

. Significant courses included: Strategies for Quality and

Productivity, Industrial Organization, Managerial Training &

Development, Quality Control, Production Cost Analysis,

Accounting, Economics, Statistics & Industrial Safety.

Internships

. Worked at Raybestos Products Company where major professional

duties consisted of researching and writing technical manuals.

. Worked at Egyptian Lacquer Manufacturing Company where I

conducted a Malcolm Baldrige Quality Award Assessment Program.

Graduate Work

INDIANA WESLEYAN UNIVERSITY - Cincinnati, OH - 3.96 on 4.0 Scale (GPA)

2007-2009

Master of Business Administration;

. Significant courses included: Analysis & Decision Making,

Principles of Self- Management, Fundamentals of Executive

Management, Managerial Ethics, Financial & Managerial

Accounting, Marketing, Applied Economics, Organization

Development, Managerial Statistics, and Corporate Finance.

Special Projects

. Conducted a research project consisting of a presentation about

Lincoln National Life Insurance Company's: Vision, goals,

objectives, services, financial information and market strategy.

. Researched and developed a Financial Analysis on The Hershey

Company which included the following information: Overview and

history of the company and its product lines, evaluation of

senior management, overview of nearest competitors, weighted-

average-cost-of-capital, rationale/methodology for evaluating

capital budgeting opportunities, economic forecast for the

industry, international markets and forecasts, characteristics

of common stock, characteristics of bonds, and key financial

ratios.

. Researched and developed an Economic Analysis on General

Electric which included the following information: Overview and

history of the organization including relationship to

international connection, key defining company moments, sales

and financial statements, key products and services provided,

policies and strategies for pricing, marketing, distribution,

nature of market structure, technology and new product

information, consumer perception of the firm and products,

workforce - makeup, labor conditions, productivity information,

and benchmarking data versus competition.

Peter S Gibson page 6

GRAPHIC PACKAGING INTL. - SCHOOL OF LEAN SIX SIGMA 2009-

2010

Lean Six Sigma Black Belt Certification

Special Projects

. In 2010, improved the overall net effective output (NEO) from

10,666 cartons per hour (CPH) to 15,012 cartons per hour (CPH)

on an Alpina Gluer which resulted in an annualized cost savings

of $407,840.

. In 2010, improved the overall net lineal feet per minute (NLFPM)

from 140.67 to 175.71 on a Komori Press which resulted in an

annualized cost savings of $164,160.

THE OHIO STATE UNIVERSITY - Columbus, OH 2010

Leadership Training & Certification

PROCTER & GAMBLE COMPANY - Cincinnati, OH 2010 -

2012

QAKE Certification as Trainer/Auditor

QI Elimination and Validation Certification

Supplier Root Cause Analysis Certification

CINCINNATI STATE UNIVERSITY - Cincinnati, OH 2011 -

2012

Industrial Electrical Maintenance Certification

Achievements

. Member of Sigma Phi Epsilon Alumni Chapter (Purdue University)

. Golden Cone Award Recipient for outstanding cost savings achievement

in Continuous Improvement initiatives (Edy's Grand Ice Cream)

1995

. Target Achievement Award Recipient by meeting all administrative cost

control, material yield, quality and customer satisfaction and

inventory

control initiatives (Da-Lite Screen Company)

2000-2005

. Operational Excellence Award for cost, quality, delivery

and lean manufacturing achievements (Altivity Packaging)

2007

. Member of American Society for Quality (ASQ)

References Available Upon Request



Contact this candidate