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