Douglas C. Blasius

***** ***** ******** **** / *******, IN 46783

260-***-**** (home) / 260-***-**** (cell) / abh6rf@r.postjobfree.com

November 9, 2010

Dear Sir/Madame,

Ref: Production Manager - Fort Wayne

This is in response to your posting for a Production Manager opportunity in

the Fort Wayne area. To summarize my background:

Production:

. Full plant production responsibility for teams of 40 to 150

employees with multiple manufacturing operations, cost centers

including Safety, Manufacturing, Quality, Maintenance,

Shipping/Receiving, Engineering, Inventory and ISO.

. Developed proposals, managed materials/supplies, capital budgets and

all expenditures.

. Implemented Lean practices (6S, inventory management, warehouse

layout), reducing scrap 11%.

. Developed and implemented policies and six sigma metrics resulting

in increasing operating income 275%, lowering labor costs 17% and

increasing output 27%.

. ASQ - CERTIFIED Lean Six Sigma Black Belt

Coaching/Training:

. 24/7/365 operations in both union and non-union high speed

(automotive) manufacturing settings.

. Mentored, and empowered team members, thus guaranteeing consistent

performance and quality of product produced, while fostering

employee improvement and safety.

. Directly influential in improving production 17%, 20% reduction of

unscheduled downtime, and reduction of employee turnover.

. Designed and trained 440 people in 4-day Participative Management

Skills course which helped operations meet the 5 year objectives in

just 2 years.

. Modeled behaviors thus instilling accountability, collaboration and

trust which engaged all team members.

Management:

. Actively involved with daily operations (pulse on the floor),

provide required leadership, vision, improvements, business

strategies, listen and act on the voice of the Customer.

. Implemented lean manufacturing (JIT, Work standards, Kanban and

material pull systems) and continuous process improvement (which

included quality practices, SOP, SPC tracking and various

Benchmarking standards) to increase production and labor

utilization, which included being actively involved with daily

operations (pulse) on the manufacturing floor as a change agent.

. The liaison / point of contact between customers, operations and

sales at multiple automotive assembly plants.

Quality:

. Achieved 22% reduction in quality issues, implementation of cost

effective Lean /Six Sigma methods.

. Key and contributing member of team responsible for achieving ISO

9002 registration.

. Board Member of Berkshire Council for Quality.

Product Development:

. Designed a new product for GAP and produced it five days later which

exceeded customer expectations.

. Developed new products based on customer desires, salesmen opinions

and customer feedback.

. New product creation, business development and trials from

manufacturing to approval and issue resolution.

I have enclosed my resume with further detail of my qualifications and

accomplishments. I look forward to meeting with you to discuss how I may

fit into your clients' organization and add to their professional staff as

Production Manager.

Sincerely,

Douglas C. Blasius

Enclosure

Douglas C. Blasius

10540 South Vinewood Road / Roanoke, IN 46783

260-***-**** (home) / 260-***-**** (cell) / abh6rf@r.postjobfree.com

Production Manager

Management-Quality Engagement

Summary

V Effective self-starter demonstrating over 20 years of solid experience

across varied products, services and technologies across union and non-

union manufacturing operations.

V Creative, highly energized professional with outstanding communication

skills and visionary problem solving ability.

V Combines "hands-on" technical qualifications with consistent success

in identifying opportunities for improving safety performance,

operating metrics and reducing costs.

Strengths:

$MM Revenue & Profit Maximization

Recordable OSHA Injuries Reduction

Short / Long Term Strategic Planning

Product / Process Design & Implementation

New Product Introduction

Complex Union Contract Negotiations

Union / Non-Union / Seasonal Staffing

Innovative Problem Solving Techniques

Tools:

TQM / Kaizen

IOSHA / OSHA

ISO 9000 / QS9000

5S/ SPC/Six Sigma

Coaching / Training

ASQ Lean Six Sigma Black Belt

APQP / PPAP

Just In Time (JIT)

Preventive Maintenance

Concentrations:

Safety Compliance

Continuous Improvement

P & L / Budget Management

Team Building

Lean Six Sigma

Project Management

Process Development

Regulatory Compliance

Waste & Cost Reduction

Manufacturing Environments:

Environmental / Tier 1 and 2 / High Volume / Automotive Assembly Supplier /

Specialty Paper

Credentials & Professional Affiliations

Bachelor of Science - Engineering Administration - Michigan Technological

University

Bachelor of Science - Mechanical Engineering - Michigan Technological

University

Certified Six Sigma Black Belt - ASQ (#10331)

Local Business Representative to State Career Majors Initiative

Chapter Vice President of Association of Plant Engineers

Board Member of Berkshire Council for Quality ASQ Member

EMTC Advisory Board Member

ARC/Special Olympics Volunteer Partner

As ARC VOLUNTEER, assisted operations by reviewing and installing

equipment, training, creating and writing standard operation/ work

procedures, along with work flow (5S) modifications.

Professional Progression & Select Accomplishments

CUSTOMER ENGINEERING MANAGER / Visteon Corporation / Fort Wayne, IN

(Contract 9/2005-4/2010)

Primary point of contact for customer, quality, engineering, technical

problem resolution in product launches.

> 23% Reduction in quality concerns, 28% reduction in quality charges.

> Coordinated part introduction, trials and integration in 38 product

changes and launches.

> Utilized Lean Six Sigma tools (8D's, Cp, Cpk, poke-yokes), improved

quality by 21%.

PLANT MANAGER / Vita Nonwovens / Fort Wayne, IN (Contract 4/2005-9/2005)

Nonwoven Products. Responsible for; Fort Wayne site-production, safety,

QS9000, quality, engineering, logistics, scheduling, training/hiring, HR,

maintenance, materials/supplies, budgets and G & O, through plant

closure.

> Implemented Lean practices (5S, inventory management, warehouse

layout), reducing scrap 11%.

> Reduced direct and indirect labor 19% while maintaining output.

> Improved material flow and utilization, reducing waste by 7%

PRINTING OPERATIONS MANAGER / Stumps Printing / South Whitley, IN (7/2003-

11/2004)

Customized Printing Products. Responsible for; all production, safety, on-

time shipping, scheduling, capital/process improvements, training/hiring,

materials/supplies and G&O.

> 26% reduction in quality issues, 21% reduction in labor/supply cost.

> Created, implemented and operationalized 7 new product lines.

Douglas C. Blasius

Resume / Page 2

PLANT ENGINEER / Smurfit Stone Container Corp. / Wabash, IN (3/2002-6/2003)

Coated Boxboard Manufacturer. Responsible for; assigning, directing,

motivating and monitoring engineers and projects; ensuring efficient and

effective operation of powerhouse; identifying and resolving

projects/issues; assuring compliance of waste water treatment plant; and

directing maintenance.

> Coordinated gas fired boiler start up plan, eliminating ineffective

and outdated steam system allowing continued plant operation and

maintained compliance with Environmental permit constraints.

> 15% Reduction in OSHA recordables.

> Implemented predictive maintenance programs and created skill

improvement plan to reduce downtime.

PLANT MANAGER/OPERATIONS MANAGER / Crown Vantage (James-River) /Adams, MA

(1993-2001)

Specialty Paper Manufacturer and Converting. Responsible for; ensuring

customer expectations were met; cost analysis; establishing and

implementing air environmental requirements; monitoring ISO processes;

contract negotiations; P & Ls; improving performance; and monitoring

safety standards.

> Introduced and implemented "Industry-First" 96-hour turn-around

program.

> Created, directed and managed Federal air permits including Title V

registration to ensure compliance.

> Reduced lost time injuries by 45% through employee education and

corrective actions.

> Sourced, procured and installed used equipment, saving $2.5M in

project start-up.

> Negotiated Union contract implementing pay for skills plan.

> Implemented proactive management and TQM program improving good

product produced 17%.

> Led total restructuring for engineering, power plant, utilities and

maintenance (titles, duties, pay, work expectation and scheduling)

resulting in 20% reduction in unscheduled downtime.

> Negotiated utility contracts resulting in annual electric power

reduction of $140K while being awarded $485K for process improvements

by utility and special tax relief from city.

> Designed and activated preventive maintenance and power distribution

program, creating 74% reduction in maintenance call-ins and 40%

increase in electric generation.

MAINTENANCE MANAGER / Eastern Fine Paper / Brewer, ME (1990-1993)

Book and Coated Paper Industry. Responsible for; managing and directing

maintenance department; monitoring equipment operation; working with

state agencies to maintain compliance with regulations; providing

direction and implementing training to improve maintenance systems.

> Restructured 63 person maintenance staff improving effectiveness and

reduced costs 18%.

> Designed and activated Preventive and Predictive Maintenance and Power

distribution programs improving utilization of maintenance man-hours.

> Designed and implemented State of Maine approved Apprentice Program

for 5 trades.

HUMAN RESOURCE MANAGER / Howard Paper Mills / Dayton, OH (1989-1990)

Specialty Book and Paper Industry. Responsible for; management of

employee performance and corrective actions; creating policies and

procedures; implementing team skills and training; and managing and

resolving labor issues.

> Reestablished Human Resource Department from ground up, including

organization structure, policies and procedures, pay structure, and

hiring and termination customs.

> Designed and implemented new policies, procedures, compensation pay

for performance system and HRIS.

> Organized safety and housekeeping reducing recordable injuries 22%.

> Successfully dealt with grievances resulting in "no arbitrations".

ORGANIZATION DEVELOPMENT & MAINTENANCE MANAGER / Miami Paper Mills /

Dayton, OH (1985-1989)

Book and Paper Industry. Responsible for; developing social and

technical training for employees; creating effective non-union

environment; and monitoring organization to ensure proper direction.

> Successful startup of non-union converting and international

distribution center in West Chicago.

> Developed and implemented policies to create non-traditional paper

mill operation leading implementation and successfully trained 440

employees in team skill and problem solving program, increasing

operating income 275%, lowering labor costs 17% and increasing output

27%.

> Maintained and operated all paper mill equipment during labor strike

keeping operation functioning.

> Effectively managed post-strike affairs, replacing and training 80% of

employees.

> Developed and directed expense and capital projects for paper mill,

utilities/treatment and facilities.

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