Manager Plant

Jon Lyons

** ****** ****, **********, ** *****

Cell: 508-***-****

Home: 508-***-****

Email: ********@*****.***

Operations Executive

OBJECTIVE: Proven executive pursuing an opportunity to lead an exciting organization to operational

excellence and world-class performance.

PROFESSIONAL EXPERIENCE

HEAT TRANSFER PRODUCTS 2009-Present

Vice President of Operations, East Freetown, MA 1/09 – Present

Responsible for 2 manufacturing plants and the distribution center for a $70M, 200 employee

manufacturer of stainless steel boilers and water heaters.

• Increased profitability from 0% to 5% EBIT by improving safety, quality, cost,

service, efficiency.

• Reduced inventory from $29M to $12M while improving customer service, inventory

accuracy.

• Hired and developed new leadership team, established focused factories and a

distribution center.

• Established a lean operations system: accountability processes, 5S, training,

standardized work, Kanban, TPM, single-piece flow, quick changeover, mistake-

proof, continuous improvement.

• Created business processes: safety committee and audits, corrective action, supplier

quality, QC charts, SIOP, demand forecasting, material review, scanning, inspection,

annual employee review.

• Introduced laser welding, improved factory automation and testing, tracer-gas leak

testing.

BERRY PLASTICS (Prior to 4/07 was Covalence, prior to 2/06 was Tyco Adhesives) 2003-2009

Regional Plant Manager, Doswell, VA and Middlesex, NJ 5/08 – 1/09

P&L responsibility for $70M, 120 person coated products and specialty tapes plants.

• Responsible for turning both plants to acceptable profitability through improved

service, quality, cost improvement, improved pricing, and new product development.

Director of Quality, Tapes and Coatings Division, Franklin, MA 10/06 – 5/08

Responsible for Quality leadership and improvement of the 15 plant, 3000 employee, $600M

manufacturer of tapes and coated products.

• Established the division quality office. Integrated multiple quality systems into an

ISO 9001:2000 corporate system. Supported plants ISO 13485, ISO 16949, GMP,

PPAP, NSF certifications.

• Reduced customer complaints by 20%. Established complaint management system.

• Led strategic customer initiatives, plant improvement projects, shop floor quality, six-

sigma.

Director of Operations, Corrosion Protection Group, Tijuana, Mexico 6/03 – 10/06

Led the 300 employee, $92M worldwide manufacture and distribution of corrosion protection

shrink-sleeves, anodes, and epoxies in Tijuana MX, Aarschot Belgium, Houston TX, and Baroda

India.

• As Tijuana Plant Manager exceeded annual plans, saved costs. Grew output 14%,

completed 18 projects that saved 15% on labor, 8% on OH. Reduced inventory from

40 to 28 DOH.

• Restructured Houston plant and drove profitability improvement from -3% to 15%

EBIT.

• Operations leader on team that established satellite manufacturing operation in

Baroda, India.

TYCO TELECOMMUNICATIONS (Prior to July 1997 was AT&T Submarine Systems) 1985-2003

Plant Manager, Tyco Optical Transmission Systems, Exeter, NH 12/00-5/03

P&L responsibility of $500M, 500 employee manufacturer of optical transmission equipment.

• Doubled revenue and quadrupled EBIT

• Employed balanced scorecard, teaming and training, Lean Manufacturing, Kanban

control, TPM, flexible cells, ERP system (Oracle), six-sigma, ISO 9001, daily

huddles.

• Nurtured supplier relationships, led EH&S programs, oversaw finance, development

and IT.

Manager of Engineering and Operations, Tyco Undersea Photonics, Clark, NJ 5/95-12/00

Led a department of 18 engineers, 8 managers, and 200 operators in production of high-

reliability electro-optical repeaters and branch units for undersea telecommunication

systems.

• Increased production five fold, reduced product costs by over 50%, redesigned manufacturing

processes, improved productivity and safety, and maintained high quality and reliability.

• Consolidated operations, reduced costs, and integrated supply chain into facility

• Redesigned product to use standard components and methods for custom parts.

Member of the Technical Staff, AT&T Bell Labs, Morristown, Holmdel, Whippany, NJ 9/85-

5/95

Statistician, Quality Engineer, Quality Manager.

• Led ISO 9001 implementation. Developed systems. Authored procedures. Managed staff.

• Developed methods for monitoring undersea cable systems, computers, factory test systems.

• Established formal quality system: charter, vision, goals, metrics, and improvement teams.

• Developed computer service measurement systems. Performed market research and

analysis.

EDUCATION

Master of Science (Statistics) – Brigham Young University, Provo, Utah 1985

Bachelor of Science (Statistics)– Brigham Young University, Provo, Utah 1984

CERTIFICATIONS, TRAINING, AND LANGUAGES:

Certificate in Labor Relations, University of Rutgers, New Brunswick, NJ 2000

Certified Quality Engineer, American Society for Quality, Milwaukee, WI 1992

Lean Manufacturing 2011-2013

APICS Supply Chain Fundamentals 2013

Six-Sigma Black Belt 2004

Plant Manager training in EH&S, Lean Operations, Change Management 2000-2006

Leadership Enhancement and Development 1997

Excellent computer and data analysis skills: MS Office, Minitab

Touch typist

Fluent in Spanish

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