Mark R. Morgan, P.E.
**** *** ********* ****, ********, TN 37069
615-***-**** ( ab9zbe@r.postjobfree.com
Engineering Operations Manufacturing Executive
Accomplished professional with blend of expertise in engineering,
operations, and manufacturing. Skilled leader with the ability to
translate high level business objectives into action that produces results.
Effective communicator both at the plant floor level and with executive
leadership. Significant experience leading various business functions;
design and manufacturing engineering, production operations, quality,
purchasing and materials management, human resources, and accounting.
Strengths & Core Competencies
Launching Manufacturing Operations Developing, Motivating, and Leading
High Degree of Engineering Capability People
Six Sigma Black Belt Problem Solving Successful P&L Experiences
Implementing Environmental, Health & Lean Manufacturing & Value
Safety Systems Engineering
Inventory & Materials Management ISO9001 & TS16949 Implementation
High Volume Automotive Manufacturing Chemical Manufacturing Experience
Experience Custom Industrial Equipment
Manufacturing
PROFESSIONAL EXPERIENCE
Avure Technologies, Inc - Franklin, TN
2012- Present
World's largest manufacturer of high pressure processing equipment for food
pasteurization.
Director of Operations
Overall responsibility to create North American Operations Center and
transfer manufacturing technology from Sweden to North America.
. Completed broad site selection evaluation within North America that
analyzed various sites with regard to logistics, business taxes,
energy costs, and incentive packages.
. Managed engineering firms and contractors that performed brownfield
facility renovation valued at $700,000.
. Managed the design, fabrication, installation, and validation of
manufacturing equipment.
. Applied for and obtained tax incentives from state and local
government worth over $290,000.
Smith & Wesson Security Solutions - Franklin, TN
2010-2012
Global provider of customized perimeter security systems for all branches
of the Department of Defense, corporate data centers and petrochemical
plants. Company services include vehicle barrier product design, security
consulting, construction management, and access control point systems
integration.
Director of Engineering
Manager of all mechanical, civil, and electrical engineering activity in
the design of custom perimeter security systems. Scope included conducting
threat assessments and performing security evaluations for clients,
generating concept and detailed designs, writing bills of materials and
technical specifications, and providing site support for installation
activities.
. Developed and introduced four new security products to market,
including two new vehicle barrier systems (SW1900 wedge barrier and
M50 Post & Cable barrier) and two enhancements for existing products
(GRAB Net Encasement and GRAB Net Retraction System.
. Lead the Project Team in CE certification process for GRAB barrier,
allowing export to Europe.
. Championed various lean projects that improved engineering department
efficiency. Specifically; implementation of AutoCAD Electric to
reduce engineering design hours and improve control panel build first
time quality, creation of standard barrier control program to reduce
programming hours, and implementation of standard site layout
templates.
. Implemented a new Change Management process to ensure engineering
changes are reviewed, validated, documented, and implemented in a
robust manner.
W.R. Grace - Mt. Pleasant, TN
2006-2010
Global manufacturer of specialty chemicals with 3.2 billion in sales and
6,000 employees. The Mt. Pleasant manufacturing facility produced roofing
underlayments, self-adhered window and door flashings, and structural
waterproofing systems.
Plant Manager
Overall site leader for all departments including production, engineering,
quality, materials management, health and safety, and human resources.
100,000 square foot facility generating annual revenue of $85 million with
55 employees operating 24 x 5.
. Leader of plant startup team; managed general contractor that
performed $2 million facility renovation and contractors that
installed custom manufacturing equipment valued at $22 million.
. Directed all site acceptance testing and startup of rubberized asphalt
mixing cell, flexographic printing line, coating and laminating line,
slitting cell, hot melt adhesive mixing cell, and robotic packaging
cell.
. Coordinated tax incentive programs with state and local government
valued at $1 million over 5 year period.
. Championed implementation of corporate Environmental, Health, and
Safety management system; consisting of process hazard assessments,
safety training, near miss reporting and safety observation program,
plant safety committee, etc.
. Implemented concept of self-directed work teams, enabling employee
engagement and ownership. Created and conducted training on shared
values to build a winning plant culture.
. Successful in creating a culture of waste elimination within plant,
resulting in an average hard cost reduction of $400,000 per year.
Projects consisted of raw material yield improvements, scrap
reduction, recycling of packaging materials, indirect material
sourcing, and energy savings.
. Lead problem solving team that reduced scrap in hot melt adhesive
manufacturing cell from 6% to <1% using statistical problem solving
tools; measurement system analysis, design of experiments, multi-
variant regression analysis.
ThyssenKrupp Budd System - Columbia, TN
2000-2006
A metal fabricator and major supplier of automotive components and systems
to automobile industry. The Columbia manufacturing facility produced in-
line-vehicle sequenced chassis modules to Saturn production facility in
Spring Hill, TN.
Plant Manager
Overall site leader for all departments including production, engineering,
quality, materials management, health and safety, and human resources.
30,000 square foot facility generating annual revenue of $55 million with
45 employees operating 20 x 4.
. Achieved zero lost time incidents in three years and zero recordable
injuries in two years due to focus on safety. This consisted of
management safety audits, ergonomic risk assessments, daily safety
talks, and safety training.
. Eliminated 3PL logistics provider by assuming internal managing of
freight, resulting in annual savings of $250,000.
. Maintained margins despite raw material price increases through
resourcing activity and ongoing focus on value engineering and
internal cost reduction.
Quality Manager
Responsible for development and implementation of quality management
system, supervision of Quality Technicians, supplier quality management,
and corrective and preventative action program.
. Collaboratively wrote and implemented documentation to achieve
certification to QS9001 and TS16949 standards.
. Facilitated APQP and lead internal and external PPAP activity for new
product launch.
. Implementation error-proofing system to eliminate operator defects.
Project consisted of integrated electronic control module for each
workstation that incorporated feedback from barcode scanners, torque
tools, and workstation tooling.
Manufacturing Engineer
Responsible for construction management of new greenfield facility,
equipment installation, and process validation.
. Performed measurement system analysis and process capability studies
on chassis module alignment machine, bushing press insertion presses,
and powered torque tools. Solved problems and reduced equipment
variation as required.
. Wrote operator work instructions and performed initial operator
training. Wrote initial quality control plan.
Saturn - Spring Hill, TN
1993 - 2000
Automobile manufacturer that operated as a subsidiary of General Motors.
Employed over 6,000 associates in a 6.9 million square feet manufacturing
and assembly complex in middle Tennessee.
Manufacturing Engineering Manager
Lead a team of seven manufacturing engineers responsible for; body panel
fit, door/hood/trunk function, and vehicle suspension alignment. Scope
included current vehicle problem solving and future vehicle tool design and
process validation.
. Lead manufacturing engineering team responsible for launch of 1999 3-
door coupe. Conducted dimensional validation of body side and door
panel stamped metal components, resistance welded assemblies, and
injection molded body panels.
Production Supervisor
Managed UAW team members in unique labor-management partnership in meeting
daily production, quality, and safety goals.
Manufacturing Engineer
Functioned as engineering resource for Chassis Assembly department.
. Installed new brake system fill and test equipment, reducing cycle
time by 10% and eliminating plant bottleneck.
. Completed problem solving projects that reduced downtime and rework in
brake fill and test area, including excess brake pedal travel due to
brake pad thickness variation and leaks at brake hose joints.
Delco Chassis Division of General Motors - Dayton, OH
1988 - 1992
Automotive component design and manufacturing company producing brake and
suspension system components, engine compartment electromechanical devices,
interior vehicle hardware, etc.
Development Engineer
Developed new automotive chassis products utilizing fiber reinforced
plastic (FRP) materials. Implemented material and process improvements to
existing FRP leaf spring filament winding manufacturing process.
. Created new technology enabling the casting of aluminum and magnesium
alloys to FRP materials. Used this new method to design and
manufacture FRP suspension links used in rear suspensions of 1997
Corvette and EV1.
. Conducted experimental study of fatigue performance vs. fiber content
in FRP leaf springs. Optimized fiber content to maximize performance.
Education
M.S. Mechanical Engineering ? Stanford University ? Palo Alto, CA
B.S. Mechanical Engineering ? Kettering University (formerly General
Motors Institute) ? Flint, MI
Technical Competancies
SAP ( SolidWorks ( DraftSight ( Minitab ( SharePoint ( MS Office ( MS
Project
HONORS & CERTIFICATIONS
Registered Professional Engineer, State of TN, License # 00114683
Member, National Society of Professional Engineers
U.S. Patent # 5,195,571 - Method of Die Casting Metal to Fiber
Reinforced Plastics
U.S. Patent # 5,385,421 - Fail-Safe Composite Cast Metal Structure
U.S. Patent # 5,392,840 - Method of Casting Fail-Safe Composite Metal
Structure
U.S. Patent Application # 13/586,017 Wedge Shaped Vehicle Barrier with
Sling
General Motors Fellowship Award -1989
General Motors Boss Kettering Award - 1996
U.S. Army Corp of Engineers Construction Quality Management
Certification - 2011
Society of Military Engineers, Huntsville District - Engineer of the
Year Award - 2012