STEVE EWART

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

CELL: 843-***-**** : ab9iyk@r.postjobfree.com

Open To Relocation

PROFESSIONAL SUMMARY

Results oriented and decisive leader with 14 years of manufacturing management experience including extensive

experience developing and managing teams ranging from 30-person shifts to a 290-employee plant. Proven

expertise in team development and training, process development and improvements, plant logistics, and plant

growth. Experienced managing a plant startup from the permit stage through construction to operation start-up..

CAREER HIGHLIGHTS

• • Adept at managing large scale budgets (up to

Experienced at leading large manufacturing plants.

• $75M/year)

Experienced at managing a $221M plant startup.

• • Experienced in 5S methodology, value stream

Experienced in both the battery manufacturing and

battery recycling industries. mapping, and LEAN manufacturing processes.

• • Awarded Manager of Safety Plant of the Year 3

Accomplished in personnel and team development.

• times.

Experienced in short term and long term planning

• Skilled at manufacturing the highest quality

with a global operations environment.

products.

ACCOMPLISHMENTS

• Oversaw $221M construction project, met and exceeded all environmental standards, managed the

development and execution of detailed hiring (290 personnel) and training programs for the first battery

recycling center to be permitted in the United States in the last 20 years.

• As Plant Manager of the Ft. Wayne Battery Distribution Center (JCI), managed plant to 30% formation

and shipping production increases from May, 2005 to August, 2010.

• While Plant Manager at Ft. Wayne, the plant won the Johnson Controls Power Solutions Safety Plant of

the Year award in 2006, 2008, and 2009.

• At Ft. Wayne, developed extensive employee engagement action plans which saw the plant receive the

second highest combined employee engagement (Employee Engagement and Leader Effectiveness)

scores (80% approval) for Power Solutions in 2009 and first overall (83% approval) in 2010.

LEAN MANUFACTURING ACCOMPLISHMENTS

• Increased Formation production from 72 batteries per person hour (BPPH) in 2005 to 103 BPPH in 2010

(30%) while reducing Production headcount 10% during same period (From 108 to 96 hourly

employees).

• Surpassed Division required Blackbelt cost reduction savings of $300,000/yr for five consecutive years

(2006-2010).

• Achieved $500K in cost reduction savings in 2009 with two key Blackbelt projects; 1) Autolabeling out of

formation (allowed us to ship Autozone and Advance orders directly out of formation) and 2) Formation

conveyor timing adjustments (eliminated gaps in conveyors).

• Originated the plan for Shipping out of Formation. Plan was so successful it was adopted by all five other

Battery Distribution Centers. Improved Shipping BPPH

• While installing 6 replacement Waterbath Formation Tables in 2009 saved 10% ($250K) on project costs

by utilizing local vendor for installation instead of Division Approved Vendor.

• Improved shipping production 40% from 2007 to 2009 (increasing from 60 BPPH to 85 BPPH) utilizing

lean and 5S principles to redesign decorating stations, allowing employees to execute battery

changeovers without having to leave the line to get components.

• During Recycling Center start-up reduced salaried headcount footprint 18% (from 64 to 54 personnel) by

consolidating responsibilities and contracting some engineering and maintenance tasks out, resulting in

$500K budget savings.

EXPERIENCE

Johnson Controls – Power Solutions Mar 1999 to Mar 2013

Battery Recycling Center Plant Manager, (August 2010 to March 2013) Power Solutions – Florence, SC

• Managed Battery Recycling Center start up.

• Oversaw construction from building permitting, design, through to complete construction, ensuring project was

in environmental compliance.

• Managed first of its kind, state of the art recycling center that had 64 salaried and 265 hourly personnel and at

full capacity will crush 15,330,000 batteries/yr and produce 132K metric Tons of lead/yr.

• Developed and managed yearly operations budget of $70M/yr.

• After two and a half months of operation, the Florence Recycling Center foundry was the highest producing

foundry at 107 metric Tons/furnace/day in Johnson Controls.

Distribution Center Plant Manager, (May 2005 to August 2010) Power Solutions – Ft. Wayne, IN

• Responsible for managing 120 employee (24 salaried, 96 hourly) Battery Distribution Center.

• Plant formed and shipped an average of 4.5M batteries/yr to customers.

• Plant production improved 30% over five year period.

• Introduced shipping out of formation using an auto labeler to division that increased batteries per person hour

(BPPH) by 15.

• Power Solutions Safety Plant of the Year for 2006, 2008, and 2009.

• Achieved highest combined Employee Engagement scores for Power Solutions in 2010.

Plant Superintendent, (October 2003 to May 2005) Power Solutions – Geneva, IL

• Manage floor operations for 300 employee integrated battery plant.

• Oversaw everything from plate making, pasting, cast on strap (COS), forming, and shipping.

• Increased formation production by 15% from November, 2003 to May, 2005 by reducing personnel and

improving formation times.

• Plant was named "Most Improved Plant" for Power Solutions in 2004 for having the great overall plant

improvement year over year.

Distribution Manager / Distribution Supervisor, (March 1999 to October 2003) Power Solutions – Canby, OR

• Managed formation, shipping, truck loading, customer service, and assigned maintenance (80+ personnel) for

Canby, OR battery plant.

• Developed and implemented formation scheduling program that resulted in a 40% increase in production

(from 10,000 batteries/day to 14,000 batteries/day) over a two year period.

• Ensured all Supervisors were trained on all equipment and given additional responsibilities beyond their

natural scope, resulted in one of the Supervisors becoming the Production Control Manager for the plant and

the other becoming the Shipping and Formation Area Manager.

U.S. Army (Armor Corps) 1986 to Mar 1999

Armor Officer, November 1986 to March 1999

Armor Platoon Leader, 1987-1989, Ft. Carson, CO

Armor Company Executive Officer, 1989-1991, Ft. Carson, CO

Brigade S3 Operations Officer, 1991-1992, Korea

Armor Company Commander, 1992-1993, Korea

ROTC Instructor, University of Rio Grande, Rio Grande, OH, 1993-1996

National Guard Advisor, Idaho, 1996-1999

EDUCATION

Bachelor of Science: Business Administration, 1986, Norwich University – Northfield, VT.

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