Manager Quality Assurance

Ed Smart

*** **** ******* ****** ****** Arrow, OK 74012

859-***-**** (Cell) ***********@*****.***

EXECUTIVE PROFILE

• More than 20 years of operations management and leadership experience in manufacturing environments and

plants with as many as 574 personnel. Repeatedly successful in increasing financial performance, productivity, quality,

safety, service, and customer satisfaction. MBA earned with honors from University of Redlands, Redlands, California.

• Strong champion of Lean Manufacturing and Six Sigma Culture. Successful in

creating Lean, Six Sigma culture within a $150+ million operation, driving continuous improvement throughout the

organization. Utilized Key Process Indicators to accurately gauge the health of the organization and pinpoint areas for

enhancement.

• Achieved series of quantifiable accomplishments as plant manager with Dal Tile,

including 43% increase in productivity, 8% overall equipment effectiveness increase to our bottleneck operation, 21% per

square foot reduction in costs and 20% labor reduction

PROFESSIONAL EXPERIENCE

Dal Tile

($3 billion subsidiary of Mohawk Industries with Multiple US and Mexico facilities. The Muskogee plant supplies the United States, Canada,

and Mexico Housing, Remodel, and Commercial markets with Porcelain and Ceramic floor and wall tile. Processes include Milling and

spray drying of raw materials, high volume kiln firing, automated equipment, and automated inspection equipment.)

PLANT MANAGER, Dal Tile – Muskogee, OK (2007–Present)

Promoted and charged with full responsibility for all functions and activities within plant generating up to $150 million in revenues on a

$97 million annual budget. Lead team of 6 direct report managers and up to 574 indirect reports; oversee all operations, accounting,

engineering, quality, materials, and budgeting/forecasting. Consistently lead facility to meet/exceed annual operating plan with high

customer satisfaction and quality ratings. Focus on differentiating business in a cost competitive market. Developed low cost, flexible

manufacturing process that boosted productivity by 43%.

• Restructured leadership team from a departmental structure to a value stream structure.

Engaged team in developing business plan aligned to corporate vision. Cascaded Key

Performance Indicators (KPI’s) through policy deployment to all levels of the operation. Led

team in meeting/exceeding goals annually on metrics that included customer satisfaction, safety,

operational performance, cash flow, and profitability.

• Reduced overall costs by 21% per square foot by implementing Standards in all operations

resulting in lowering waste and reducing labor requirements by 20% and implemented an

energy management system that resulted in the lowest energy consumption per square foot in

the plant’s history.

• Achieved series of quantifiable accomplishments as plant manager with Dal Tile, including

43% increase in productivity, 8% overall equipment effectiveness (OEE) increase to bottleneck

(kiln) operation.

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Ed Smart

304 East Wichita Street Broken Arrow, OK 74012

859-***-**** (Cell) ***********@*****.***

• Delivered more than $14 million savings in 2 year period. Established Six Sigma culture

throughout the facility, employees trained in “Manage by Fact” problem solving process, 3

certified Blackbelts and 10 certified Greenbelts.

• Reduced employee turnover from 57% to 2.8% within 3 years through employee surveys,

employee engagement, competitive pay structure. Provided greater sense of achievement to

associates through work design and visual KPI’s for real time feedback to daily goals.

• Reduced OSHA Recordable Incident Rate by 62% through implementation of integrating

Job Hazard Analysis into our Standard Work to identify unsafe acts, unsafe conditions, and

ergonomics in a predictable environment. Additional education was provided at all levels

through 10 hour certification classes and safety huddles that presented OSHA 1910 concepts

into the work environment. Awarded VPP in 2011.

GENERAL MANAGER – Campbellsville, Kentucky, Aug 2005 – May 2007

Responsible for plant wide operations of a travel trailer manufacturing facility, with annual sales in excess of $45 million

dollars. Increased operating profitability, growth of sales, and expansion of product offering. Responsible for all facets of plant

operations including Production, Human Resources, Purchasing, Internal Sales, Service, Budgeting, and Safety. Applied lean

manufacturing activities resulting in increased capacity, increased revenues, reduction in overall costs.

• Increased plant capacity by 60% resulting in increased revenue of 73% and reduced Labor

Costs of 30%.

• Successfully shifted from a build to stock to make to order manufacturing model resulting

in the highest Customer Satisfaction Index ratings in the division with the highest Return on Sales in the division.

• Maintained one of the lowest worker’s compensation as a percentage of sales in the

Division.

DIRECTOR OF MANUFACTURING RV Division Jan 2005 – August 2005

Responsible for coordinating the manufacturing strategy across both the Motor Homes Division and the Travel Trailer Division

Achievements:

• Headed the operational team for implementing J D Edwards Oneworld ERP system across the corporation.

• Worked to standardize manufacturing methods across divisions with the adoption of best practices

• Produced product rationalization plan for all plants

• Member of strategic steering committee tasked with organizational restructure to support strategic direction

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Ed Smart

304 East Wichita Street Broken Arrow, OK 74012

859-***-**** (Cell) ***********@*****.***

REGIONAL GENERAL MANAGER – Eastern Region Apr 2004 – Jan 2005

Responsible for two plant operation with the main task of turning one plant around and implementing a start up at the second.

• Successfully applied lean manufacturing techniques to existing plant resulting in achieving profitability

• Increased capacity by 15%

• Increased revenue by 25%

• Reduced Labor as a percent of sales from 25% to 17%

• Successfully opened new facility to full production

Additional Experience:

• General Manager – Fleetwood Campbellsville, Kentucky 2002 – 2004

• Project Manager – Fleetwood – ERP Implementation Riverside California 2000 – 2002

• Production Manager Manufactured Housing Fleetwood– Rocky Mount, Virginia 1997 – 2000

• Plant Manager Buckeye Fire Equipment – Kings Mountain NC 1996 1997

• Alger Manufacturing – Director of Quality Assurance Ontario, California 1991 1996

• Dense Pac Micro Systems – Quality Assurance Manager Garden Grove, California 1989 1991

• Northrop – Grumman – Quality Assurance Manager on MX Missile Program Hawthorne, California

1985 1989

• United States Air Force Electronic Warfare Specialist 1980 1985

EDUCATION & CREDENTIALS

Masters of Business Administration (MBA), with honors – 1996 University of Redlands, Redlands Ca

University of Redlands, Redlands Ca

Bachelor of Science in Business and Management (BSBM) – 1992

Professional Affiliations:

• Muskogee Development Board of Directors – Muskogee OK

• Northeastern State University Panel Member Participant – Muskogee OK

• World Energy Engineering Congress Panel Member Participant – December 2010 Washington DC

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