Russell Ballard

**** *** ******** **** **********, KY 40291

ab9kkd@r.postjobfree.com 502-***-****

Objective To further my professional career to the mutual growth and success of myself and

Toyota Boshoku.

Qualifications I have managed and directed injection molding and manufacturing departments, for

the world’s largest custom molder, world’s largest propriety molder. I have also

been a leader in cost reductions and Kazen activity in every organization of which I

have been employed.

Employment

05/2006 – Present Trim Masters / Toyota Boshoku Bardstown KY.

Process Engineer / Molding Manager

Transformed molding department from high scrap, high cost, poor performing

department to recognized leader in North America and one that rivals the best in

Japan.

Reduced injection scrap from 5% to current level of less than 1% through

tooling / process enhancements and in depth training of technicians through

internal and external instruction.

Began grinding runners and scrap parts and using the regrind in production

resulting in a $400,000 dollar reduction in materials usage. I also champion this

activity in 3 other facilities

Reduced use of paint and Perfix to hide flow lines on several products through

tooling enhancements and process changes saving $800,000 a year in added

labor and material.

Cost Leader (Gentani Leader) all North American plants working on process

and cost improvements in injection molding.

Built excellent working relationship between technicians, supervisors, and

operators improving moral and performance in all areas.

Instituted standard work methods for purging and color changes that resulted

in cost reductions not only in my home facility but 3 other North American

facilities of over $500,000 so far!

Injection Department leads our facility in cost reductions, and Kazen activities.

Manage molding budget and overhead cost for injection molding.

06/2001-05/2006 Summit Polymers Elizabethtown KY.

Engineer

Insured all injection molds and press side assemblies met targets in areas of

scrap and cycles.

Tracked and managed all mold pm’s and insured presses were repaired and

running without endangering the customer.

Performed in and led quality circles working with internal and external

customers to achieve desired results.

Led mold change teams and reduced change over times and from 25 minutes

on average to 15 minutes over a 6 month period without adding additional

equipment.

Transferred in and set up several injection presses.

Worked with several different departments other than molding doing root cause

analysis and implementing counter measures.

Filled in on several occasions as needed managing assembly, paint, and

molding when needed.

07/1996 – 03/2001 Mattel Murray KY.

Production Manager / Senior Industrial Engineer

Oversaw the transfer of a different product line into the facility we went from

small cube product to large cube when Mattel closed the Fort Wayne plant.

Developed a conveyor system in assembly that not only reduced material

handling of line by 75% but also tracked schedule adherence and informed

associates as to goal versus actual.

Developed pick to light assembly stations and in line weigh scales reducing

missing parts by 95%

Introduced and setup metal fabrication area in the plant including stamping,

bending, welding, and riveting which had never been done before in the facility.

Developed a milk run system for planned material delivery reducing material

handlers on lines by 50%.

Placed gravity feed flow racks on the assembly lines to aid standardized work,

reducing unscheduled down time.

Linked several of the metal fabrication in series to eliminate multiple part

numbers and independent batch processes.

Designed and Implemented light duty restricted work area to reduce our

workers compensation cost.

When the operations manager left, the molding manager, maintenance

manager and I (production manager) were asked to fill in as a group until he

was replaced. After two months our results led to us all joining staff and running

operations jointly, we each were awarded Mattel corporate manager of the year

award.

07/1978 – 07/1996 DJ / Nypro Louisville Ky.

Lean Manufacturing Manager

Developed a knowledge based training program for all employee’s resulting in

a skill based pay system.

Developed a just in time plant within the plant to service our just in time

customers

Transformed the assembly area from an area we managed just to service our

customers to a profit center. Went from losing $90,000 per year to making

$320,000 per year profit.

Worked directly with Toyota on Implementing the Toyota production system

throughout the plant

Toured plants throughout the United States with Toyota and helped within their

facilities implementing various aspects of T.P.S. specializing in quick mold

change and standard work.

Operations / Plant Manager

Managed all areas of manufacturing

Grew the business from 24 presses to 80 presses.

Increased efficiency and utilization from 78% to 94% with posted goals and

performance throughout the plant.

Developed a production control department introduced Performance efficiency

targets and area managers directly involved setting goals and targets.

Received numerous awards for delivery and quality from our customers

Implemented de-coupled molding

Education 1980 - 1982 Jefferson Community College Louisville KY.

No degree / Business

Visual Controls

Micro soft Word / Excel / Project

Single Minute exchange of dies

Facilitating teams

Continuous Improvement

Finance for non-financial managers

One Piece Flow

Conflict resolution

5,S

Standard Work

Trained by Toyota manufacturing in lean manufacturing

Worked with Toyota on implementing various factions of T.P.S. at their

suppliers through Bluegrass Automotive Manufacturing Associates (BAMA)

As DJ incorporated ( B level )Represenative.

Contact this candidate