Dennis D. Beckley

**** ** **** **, ******, Iowa *0021

Phone: 515-***-****

abh81i@r.postjobfree.com

HIGHLIGHTS

Operations / Leadership / Process Improvement / Commercialization / Change

Agent / Engineering

Change Management Multi-Plant Leadership Lean Manufacturing Implementation

Performance turnaround HPWS Value stream mapping

Facility optimization Start-up Leadership Strategic Planning

Product Project management Engineering and Maintenance

Commercialization Management

EXPERIENCE

Mrs. Clark's Foods, Ankeny, Iowa 5/2008-10/2009

Branded, co-packer, and private label manufacturer / bottler of shelf

stable juices, sauces, dressings and mayo type products for national and

international distribution.

Director of Operations

Directed manufacturing operations for two facilities (Hendersonville, NC

and Ankeny, IA).

. Turned around an 18 month trend of negative absorption (up to

$175,000/month favorable)

. Increased throughput by up to 40%

. Increased schedulable hours while reducing direct labor costs

. Presented accurate and integral monthly updates to Board of Directors

. Implemented SPC for weight control and capping quality across a

product portfolio consisting of juices, mayo, marinades, dressings,

and sauces ($140,000 savings)

Schwan's Global Supply Chain 7/2006-5/2008

World's largest frozen pizza plant producing primarily Tony's and Red

Baron pizza.

Manufacturing Manager, Salina, Kansas (1 year 11 mos)

. Directed 1100+ non-union employees (1800 on site) including 5

managers and 32 supervisors covering a 24/7 operation including

manufacturing and sanitation delivering nearly $1.0 Billion in sales

revenue

. 9 Bakery lines producing pizza crusts to 7 topping lines

. Led the Best Value leg of the strategic goals (>$6 M in savings

annually)

. Increased capacity in two oversold areas by 18% through conversion

to 20+ hour schedulable days

. Developed and implemented strategic execution teams encompassing all

plant supervision which led to meeting plant goals through improved

employee engagement at all levels

. Sponsor facility's lean initiatives including Visual Factory, Value

Stream Mapping, Kaizen events for 5S and quick change, and the

implementation of the facilities SPC program for weight control

. Reporting teams managed the startup of 2 new ovens, one major asset

reconfiguration project, the expansion of High Performance Teams

(HPO / HPWS), and a bakery capacity expansion program

Bush Brothers & Company (Bush's Baked Beans) 2000-2006

Production Manager, Augusta, Wisconsin (4 years 8 mos)

. Managed manufacturing, maintenance, fabrication, and facility

(water, waste water, and boilers) departments

. Organized and developed the maintenance group into a high

performance self-directed work team (HPO / HPWS)

. Implemented TPM, Total Productive Maintenance

. Initiated and led facility's relationship with Wisconsin's Focus on

Energy program

. Selected two "lean champions" to continue pursuit of lean

manufacturing using Kaizen events

. Lean initiatives included the implementation of 6S, SMED, Visual

Factory, Accountability, R & R Gauge, and Rate Based Planning.

The implementation of Lean Initiatives resulted in:

. Increased schedulable / running hours from 90 to 108 hours per week

. Improved schedule adherence to 95%

. Increased the number of changeovers by 120%

. Increased throughput by 20% on average

. Reduced quality hold issues while reducing consumer complaints by

35%

. Increased third shift role from sanitation only to include

production and changeovers

. Experienced over 4 years without a lost time accident

Dennis D. Beckley

Page 2

Technical Services Manager (Engineering Manager), Dandridge, TN (1 year 4

mos)

. Directed/coordinated: process and project engineering, regulatory

affairs relationships, contractor management, wastewater and

irrigation, process/potable water treatment, and farm operations

. Design team member of $100 million state of the art new plant

. Developed and managed $400,000 in capital projects

. Developed and managed bulk bean unloading and bulk bag filling

project

. Re-commissioned hominy production area to full capacity

Production Manager, (Interim) Dandridge, TN (4 mos)

. Elimination of $80,000 / month negative material usage variances

. Increased production utilizations between 10-25ppt

. Reduced recordables from 8 per month to 1 using the Safe Start

approach

Oscar Mayer / Kraft Foods,

1990-2000

Manufacturing Engineering Manager, Newberry, South Carolina (1 year 9 mos)

. Directed four engineers and one CAD technician for a facility

employing over 1600 associates. Staff managed CI projects,

capacity optimization, established labor requirements, pay

rates, and ergonomics

. Developed and managed capital plan for profit improving

projects ($275K in 1999, $675K in 2000)

. Developed tracking tool for cost reductions with strategic 3

year forecast horizon

Major projects initiated or executed included:

. $12.2 Million in annual productivity savings

. $20+ Million in active facility expansions for Raw to Ready to Eat

separation including employee welfare areas and new-finished goods

distribution warehouse

. 14% increase in raw capacity achieved

Process Team Senior Manufacturing Engineer/Project Manager Madison, WI

(3 years)

. Co-led with marketing, a cross functional team consisting of

Operations, logistics, and R & D focusing on: Process and product

improvement and commercialization, capital and cost reduction

budgeting, and facility planning and corporate resource allocation

. Over 25 new products, 35 cost reducing, and 15 quality enhancements

. Annual team cost reductions up to $6.2 Million (exceeding budgeted

targets)

. Designed and led the $1.1 Million capital reconfiguration of the

Sigourney facility

. Completed West Liberty, Iowa facility closure, relocating production

to South Carolina

Process Optimization Engineer, Champaign, IL (4 mos)

. Member of internal consulting team conducting comprehensive Value

Stream Analysis at the worlds largest food manufacturing facility

. Root-cause analysis of non-value added activities contributed

potential savings of $30 Million

Senior Operations Manufacturing Engineer Madison, WI (4 mos)

. Major projects included; $1.0 Million in capital appropriations,

packaging line modifications, and the development of one facility

consolidation project

Senior Industrial Engineer, Kirksville, MO (4 years)

. Responsible for all CI activity in facility, staffing requirements

for state of the art Bacon expansion start-up, variable costing

for all products, capacity planning, and site product

commercialization

. Developed and led in implementation of the Operations portion of

annual and multi-year strategic plans with implemented cost

reduction projects exceeding $7.0 Million, and capacity increases

exceeding 15%

. Chair of Ergonomic and Co-Chair of Safety Teams, which received OSHA

VPP "STAR" status

. Achieved a 42% reduction in cumulative trauma rates through

equipment and layout re-design and training efforts

EDUCATION

Master's in Business Administration, University of Iowa, completion 2012

Lean Six Sigma Black Belt Candidate

Bachelor of Science in Industrial Engineering, University of Iowa, 1985-

1990

Rate Based Planning, University of Tennessee, 2005

Program on Negotiations for Senior Executives, Harvard University, 2004

Developing Profit Center Managers, University of South Carolina, 1999

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