PAUL B. RACHIELE

***** ******** **

Home: 248-***-****

Novi, Michigan 48377 Cell: 313-***-****

abj8lo@r.postjobfree.com

http://www.linkedin.com/pub/paul-rachiele/2/409/259/

LEAN MANUFACTURING / OPERATIONS EXECUTIVE

Data Driven, Process Focused, Result Oriented

A strong leader with a proven track record of building dynamic operations

teams that emphasize process improvement and data driven decision making.

A passionate manager with demonstrated success in both plant expansion and

consolidation. A change agent with global experience dedicated to lean

manufacturing principles and best in class health, safety and environmental

programs. A rare combination of both manufacturing and sales excellence

dedicated to outstanding customer service.

AREAS OF EXPERTISE

Lean Manufacturing Process Improvement ERP Systems

Plant Rationalization Supply Chain / Environmental Health &

Logistics Safety

Cost Reduction Inventory Management Labor Contract Negotiations

PROFESSIONAL EXPERIENCE

HOUGHTON INTERNATIONAL (formerly D.A. STUART Co.) 2008-2010

$500 Million global specialty chemical manufacturer serving the automotive,

aluminum, aerospace and steel industries

Director of Manufacturing, North America 2008-2010

Led all US and Canadian operations and facilities including manufacturing

(internal and contract), inventory management, warehousing and logistics

for five plants with a staff of six direct reports and 250 indirect

reports. Responsible for efficiency improvement, cost reduction and product

quality / delivery based customer service levels.

. Orchestrated operations merger between Houghton International and DA

Stuart.

o Led plant consolidation effort resulting in the closure of 3 North

American plants and yearly operations expense savings in excess of

$7M.

o Drove inventory reduction initiative yielding a decrease in

inventory of over $3M.

o Restructured warehousing network saving over $500K yearly while

improving customer service levels.

o Established Best Practices and identified exemplary employees

resulting in the strategic retention of talent.

. Drove implementation of Lean Manufacturing and Kaizen methodologies

including process mapping, waste elimination, constraint removal, 5S,

statistical process control and Kan-Ban.

. Ensured environmental health and safety (EHS) regulatory and corporate

compliance by monitoring performance, training and reporting.

. Instrumental in the development of a Sales and Operations Planning (S&OP)

process.

. Negotiated property and equipment leases and service provider contracts

resulting in significant cost savings and strategic business

arrangements.

. Served as Supply Chain Leader for ERP system integration project.

. Partnered with Human Resource department to negotiate labor contract with

bargaining unit.

D.A. STUART COMPANY 1999-2008

$250 Million global specialty chemical manufacturer serving the automotive,

aluminum, aerospace and steel industries.

North American Manufacturing Manager 2006 -2008

Managed all North American manufacturing operations and facilities with P&L

accountability for business unit. Led staff of 10+ responsible for

implementing best practices throughout manufacturing organization including

Safety, Environmental, Quality, Production, Maintenance, Engineering,

Supply Chain and Human Resources. Tasked with establishing and overseeing

manufacturing organization's goals and objectives.

. Led global implementation of new ERP system (JD Edwards) in North

America, China and the United Kingdom.

. Served as a Member of Executive Quality Council (EQC) charged with

establishing and monitoring quality standards and addressing critical

customer issues.

. Achieved >98% On Time Shipments in North America by evaluating current

practices, implementing process improvements, improving scheduling and

tracking Key Performance Indicators all focused on superior customer

service.

. Participated in greenfield construction of a state-of-the-art

manufacturing facility in Shanghai, China.

. Realized $600K reduction in operating cost in North America by

establishing more disciplined processes and procedures.

. Implemented Material Requirements Planning (MRP) system which upgraded

planning capabilities and positively impacted inventory levels and on

time shipments.

o 15% improvement on Raw Material and Finished Goods inventory turns.

Plant Manager- Detroit Operation 2004 -2006

Managed corporation's largest multi-shift manufacturing facility producing

over 38M kilograms yearly with a staff of nine direct reports and over 50

indirect reports. Audited all aspects of employee relations including

hiring, appraisals, promotions and discipline. Responsible for the

establishment and management of Key Performance Indicators (KPI), capital

projects, budgets and EHS compliance and reporting.

. Integrated yearly volume from three decommissioned facilities into plant

with minimal disruption in production and service levels.

. Oversaw and approved ISO / TS16949 certified quality system ensuring

adherence to ongoing requirements and standards.

. Achieved >95% On Time Shipments by improving processes and scheduling.

. Realized $250K yearly reduction in Worker's Compensation premiums by

establishing disciplined behavior based safety program.

. Reduced operating cost by $750K by establishing more disciplined

processes and procedures.

. Attained 27% increase in kilograms produced per man-hour through cross

training, work flow improvements and employee accountability.

. Decreased on-hold material levels by 62% by establishing a cross

functional obsolete inventory reduction team.

Program Manager- AK Steel Rockport Works 1999 -2004

Managed company's largest Fluid Management Program (FMP) with 30 employees

and a yearly budget in excess of $30M. Negotiated contracts with customer

and suppliers. Expected to present and champion cost savings initiatives

and projects to client. Managed laboratory, lubrication services and

receiving departments. Responsible for budget establishment and compliance

. Prepared program for a successful QS 9000 initial certification audit in

November 2000 and subsequent surveillance audits.

. Developed incoming product quality system that ensured superior quality

products for customers.

. Established supplier performance tracking system that improved delivery

performance and provided critical data during contract negotiations.

. Created employee evaluation and promotion process.

. Led cost savings projects which resulted in over $250K in yearly savings

to customer.

. Assumed additional role as Account Manager from 2002-2004 for Rockport

Works and two additional customers.

o Managed sales and service with $4M in annual sales.

o Received 2002 Eagle Award for outstanding sales performance.

o Achieved $650K in new sales in 2004, $185K in new sales in 2003 and

$450K in new sales in 2002.

AMERICAN AXLE & MANUFACTURING 1994 - 1999

Multi-billion dollar global tier-one automotive supplier

Production Supervisor

Supervised daily production schedules of 40+ employees in two separate

departments. Additionally responsible for training, new hires, discipline,

appraisal, promotions and scheduling. Acted as back-up Area Production

Coordinator. Participated in union (UAW) - management bargaining process.

Accountable for compliance with OSHA safety requirements.

. Successfully led crucial restructuring of entire department resulting in

a 45% reduction in labor.

. Realized yearly increases in production levels and efficiencies by

maximizing the workforce.

. Significantly contributed as production department representative in the

initial certification and subsequent re-certifications of ISO 9001/QS

9000 standards.

. Initiated tooling study resulting in a cost savings of $60K annually and

associated productivity improvements.

EDUCATION

MBA, Finance focus, State University of New York at Buffalo 1999

BA, State University of New York at Buffalo 1995

TECHNICAL SKILLS

JD Edwards E1 Material Requirements Planning Microsoft Office

(ORACLE) ERP (MRP)

MP2 Maintenance Barcoding / scanning applications Delta V process control

software software

Time Guardian Pro Lotus Notes Infinium ERP

attendance software

MEMBERSHIPS / AFFILIATIONS

APICS member

AISE member

Alpha Tau Omega Fraternity, Board of Trustees Iota Xi Chapter

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