Manufacturing Manager

Jason W. Morrison

*** ****** ***** **** ? Cleveland, TN 37323

423-***-**** ? abh625@r.postjobfree.com

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Profile

Senior manufacturing Manager - Manufacturing professional with 12 years

experience in durable goods and medical device manufacturing. Multi-site

leadership. Stable work history and rapid advancement into positions of

increasing responsibility. Successful Lean Manufacturing implementation at

three organizations. Start-up and turn-around experience, Project

Management and Hoshin Kanri Strategic Planning and Policy Deployment.

Professional History

Jul 2010 - Present: Mayfield Dairy - Dean Foods, Athens, Tennessee: An

S&P 500 company and the largest dairy producer in North

America. Dean Foods has over 100 facilities in the US and

annual sales of approximately $23 billion.

Continuous Improvement Manager

Lead the implementation of a continuous improvement program in two dairy

processing plants and provide support to other plants in region. Develop,

plan and execute a strategy to convert processes from batch to continuous

flow. Work with HR to train organization in lean and problem solving

tools. Identify and direct improvement activity to improve safety,

quality, eliminate waste and improve process capability.

Jan 2010 - Jul 2010: Volkswagen of America, Chattanooga, Tennessee: The

third largest auto manufacturer in the world. Volkswagen is

building a world-class manufacturing plant in the US to

manufacture a new mid-sized sedan. VW's annual sales are

approximately $150 billion.

Continuous Improvement Specialist

Contract engineer responsible for development of internal logistics

systems. Develop Plan for Every Part and JIT material delivery processes

to convey raw material from receiving to point of use. Design supermarket

layout and delivery routes according to heijunka scheduling of all assembly

lines. Workstation layout and design, and standard work development.

Participate in 3P workshops to design best practice assembly processes

within takt time.

Dec 2006 - Jan 2010: DJO Inc., Hixson, Tennessee: The world's largest

orthopedic and physical rehabilitation device company with

annual sales of $1 billion. DJO's manufacturing facilities

have been awarded the Shingo Prize, IW Best Plant Award and

AME's Excellence in Manufacturing.

Director of Manufacturing and Lean

Lead the manufacturing processes of 2 medical device manufacturing

facilities. Directly manage a team of managers, supervisors, engineers,

and maintenance technicians. Drive lean manufacturing to improve

performance in safety, quality, delivery and cost. Plan and execute a

multi-departmental budget, oversee capital expenditures.

. Led project to consolidate a smaller manufacturing facility it into

another existing facility which reduced fixed overhead by $200k

. Improved lead time to international warehouses by 39%, reduced

finished goods inventory by 26%, reduced freight costs by 27% and

reduced overtime by 10% by implementing an electronic Pull System

. Improved lead time by 77%, reduced finished goods inventory by 40% and

reduced process steps by 66% by leading a kaizen blitz at a key

customer's facility to establish a Vendor Managed Inventory system

. Led manufacturing involvement with R&D to integrate Design For Six

Sigma tools into new product development to improve the quality and

ensure the successful launch of new products

. Developed Key Performance Indicators for each cell to monitor

performance in safety, quality, delivery and cost, initiated a daily

shop floor review by leadership address issues and drive daily

improvement

. Collaborated with human resources to initiate a program to achieve

OSHA VPP certification

. Introduced the first green project in manufacturing to reduce solid

waste generated by the plant

. Managed the plant closure and transition of all manufacturing

processes to new facility in Mexico

Jason W. Morrison Page 2

Lean Manufacturing Leader

Develop, plan and execute a strategy to implement lean into entire

organization. Create lean training modules and simulations. Utilize value

stream mapping to identify waste, develop the future state and target

kaizen events. Coordinate with company leadership, finance, and process

owners to plan, set goals and prioritize kaizen activity.

. Improved labor efficiencies and reduced labor cost by 25% in assembly

department through kaizen blitzes

. Cleared 35k square feet of floor space, about 30% of total, by

converting manufacturing processes from batch and queue, mass

production to cellular manufacturing paced to takt time and utilizing

one-piece flow

. Introduced organization to 5S and Quality at the Source tools to

improve process quality

. Reduced finished goods inventory by 40% by pacing production to takt

time and creating kanban systems and a plan for every part to visually

manage inventory and schedule production

Jan 1997 - Nov 2006: Whirlpool Corporation, Cleveland, Tennessee: A

Fortune 500 Company and the largest home appliance maker in

the world. Whirlpool develops and manufactures all major

categories of home appliances and has annual sales of

approximately $20 billion.

Production Manager

Lead the production and continuous improvement activities in a fast paced,

high volume, final assembly department. Directly manage a team of

supervisors, engineers and technicians. Indirectly manage 250 production

associates. Cooperate with other departments to improve performance in

safety, quality, delivery and cost.

. Achieved 6% improvement in labor cost

. New product launch team member on the successful launch of new built-

in range

Assembly Supervisor

Directly supervise 95 associates on a high volume assembly line and 2

subassembly lines. Monitor 5S, attendance, and workmanship and take

appropriate action to commend or correct as necessary. Conduct daily team

meeting to review performance and engage team in continuous improvement.

. Zero OSHA recordable accidents

. Reduced assembly defects to 98% FPY

. Improved schedule attainment by 5%

Industrial Engineer

Collect and report data on the performance of an assembly department.

Perform times studies and ergonomic studies. Develop and maintain standard

work, staffing levels, standard layout and assembly line design. Plan and

lead continuous improvement activities. Lead new product launches into

assembly department.

. Improved departmental labor cost by 26% by implementing takt time,

standardized work and utilizing kaizen blitzes to remove waste from

the production process

. Led cross functional teams in DFM and PFMEA activity to improve

processes and launch new products

. Implemented over 100 design and process poka-yokes on one new product

launch to achieve quality at the source and zero defect processes

Lean Technician Team Leader

Selected from 2000 production associates as a member of the Lean

Manufacturing Implementation Team. Led small team of technicians.

Intensive training and utilization of lean tools with Shigijitsu and TBM

consultants.

. Led over 50 kaizen events in fabrication, painting and final assembly

processes

. Led the successful 3P effort to launch a major new product into

manufacturing

Education

Lean Enterprise Systems Design Institute, The University of Tennessee, 2004

Bachelor of Science - Organizational Management, Covenant College, 2000

Certification

LeanSigma Green Belt

Kaizen Facilitator

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