Manager Quality

WILLIAM A BUCHANAN

**** ****** **. #40-256-***-****

Arley, AL 35541 *********@***.***

PLANT GENERAL MANAGER

Proven leader with over 20 years diverse management experience in

Manufacturing, specializing in increased productivity through raised

efficiencies. Decisive manager with excellent problem solving and trouble

shooting skills. Experience in building and managing self directed work

teams, Kaizen activities, 5S, Lean Manufacturing. Specific areas of

expertise include:

Cost, Scrap, & Waste reduction First time, Built in Quality

Continuous Improvement Employee Development & Training

Full P&L ownership Facility Start-Up

TS 16949/QS 9000 - ISO 14001 Environmental Health & Safety

Excellent Negotiation Skills Excellent Communication skills

PROFESSIONAL EXPERIENCE

Eagle Bend Manufacturing - Clinton Tennessee

Operations Manager

Mar 2010 - Present

Responsibilities include overseeing the turnaround (change agent) of all

production operations including receipt of material, stamping, weld

assembly, and on time delivery of quality products to numerous U.S. and

Asian OEM's. To provide leadership and mentoring to 4 Managers, 10

Supervisors and 350 employees in all areas of manufacturing including

safety, quality, productivity, profitability, on time delivery,

maintenance, production efficiencies, 5S, effective use of personnel,

ensuring compliance with all OSHA rules and regulations, and enforcing all

company policies and procedures fairly and equitably. Setting all

departmental goals, developing area metrics and tracking mechanisms (KOI's)

to allow data based decision making. Departmental P&L responsibility and

accountability to include adhering to approved budgets, tracking all

departmental purchase requisitions, evaluating any capital expenditures for

ROI.

Sewon America Corporation - LaGrange Georgia

Plant General Manager

Feb 2009 - Mar 2010

While reporting directly to the President, had total responsibility of

operations leadership from 'Greenfield" start-up to full mass production

including all safety, production, maintenance, quality, production

engineering, materials/logistics/supply chain, P&L, and tool room

activities which includes the hiring, training, and installation of all

employees and equipment. "Hands On" leadership of a continually growing

staff existing of 8 Managers, 5 Supervisors, and approximately 400

employees for a Tier 1 Korean automotive supplier of stampings and welded

assemblies. Developed and administered business unit plans including

aggressively driving cost control, ensured that plant, operation processes,

and all operational equipment are ready for SOP and that all parts meet

customer specifications while being delivered to the customer per the

shipping schedule. Coordination of all departments ensuring a smooth

startup of all new programs including conception, PPAP's, R@R, ECO's,

LVPT's, HVPT's, and shipping trials. P&L accountability which would include

plant and departmental forecasts, setting organizational business plans,

ROI, management of individual departmental budgets, strategic planning and

goal setting, and overseeing and controlling critical startup costs.

Developed "Leadership Training Program" for all management employees.

. Employing "State of the Art" technology, 3C/5S, Kaizen, Lean

Manufacturing techniques, Value Stream Mapping, KOI's etc to build a

productive and efficient company culture through the use of Mentoring

and Training of American employees.

. "Hands On" manager that leads by example and builds teamwork in a new

work force of 350 through Zero Defect built in quality mindset,

continuous improvement, and the belief that employees are a company's

greatest, most valuable asset.

. Decreased customer quality issues by 60% from 5 per day to 2 per day

through daily quality meetings, error proofing, comprehensive employee

quality training program, and proactive management approach to root

cause analysis of all internal quality issues.

. Increased on time deliveries from 40% at startup to 95% by reworking

daily production schedule, redistributing trucking usage, reduction of

quality issues which eliminated delays.

Topre America Corporation - Cullman Alabama

Plant General Manager

Feb 2004 - Oct 2008

While reporting directly to the President, had total responsibility of

leading and growing business operation from plant start-up to include all

safety, production, maintenance, quality, engineering,

materials/logistics/supply chain, P&L, and tool room activities. "Hands On"

leadership of 8 managers, 12 supervisors, and approximately 500 associates

for $80 million Tier 1 Japanese automotive supplier of stampings, welded

assemblies and fabricated parts. Developed and administered organizational

business plans, ensured that all products met customer specifications and

are delivered to the customer on time, every time. Coordinated and managed

all departments to ensure total customer satisfaction on existing programs

and smooth startup of all new programs. P&L accountability including

forecasts, ROI, and departmental budgets. Led team that coordinated

overseas supplier production, quality, scheduling, and logistics. Position

required both domestic and international business travel.

. Through the use of new technology, Lean Manufacturing, TPS, 5S,

Kaizen, KOI's, and Value Stream Mapping improved production efficiency

15% above corporate goal of 70%

. Negotiated with customer to use UT testing thereby reducing scrap and

time creating a win-win situation for both company and customer, as

well as saving approximately $70K 1st yr.

. Instituted "Built In, 1st Time Quality" keeping internal & customer

quality issues under 3%.

. Built a culture that promotes safety, continuous improvement,

increased productivity, built in quality through mentoring, coaching,

training, benchmarking, root cause analysis, data driven decision

making, performance metrics, and feedback for entire value stream

team.

. Saved $10,000 per month in stamping area through several scrap

reduction projects.

. Established and maintained efficiencies over 100% for selected areas

through use of Kaizen, value stream mapping, visual factory concepts,

training, and employee involvement.

Independent Consultant Mar 2003 - Jan 2004

Provided expertise in production processes for suppliers of International

Truck and Engine to include the processing of tooling and equipment,

production with said tooling and equipment, quality of parts produced,

production of fabricated parts, and efficient transportation of produced

parts to customer. This was done at multiple sites within the United States

and Mexico.

International Truck and Engine Corp - Springfield / Urbana Ohio May

1993 - Mar 2003

Area / Line Manager Stamping/ Assembly

Provided effective leadership, training, management, and motivation for 7

managers, 10 supervisors and 450 UAW represented employees in all areas of

production, safety, and quality control. Ensured delivery of quality

parts, in a timely manner, at the quoted labor cost to other departments

and divisions. Oversaw stamping departments, both sub and main line parts

and vehicle assembly, machining area, and fabrication and tool room areas.

Worked with purchasing, engineering, and quality to evaluate and manage

tier 1 suppliers of plastic injection molded parts. Managed multiple sites

for a $1B plus corporation.

. Along with multi-site management team, increased Stamping / Assembly

area up-time from 45% to 70% saving the company approximately $500K

through use of 5S and Six-Sigma.

. Worked with Engineering and Tool Room to design, develop, and

implement new "Dog Bone" (cross member) dies, which accounted for a

30% increase in productivity and therefore capacity allowing time for

die tryout and required preventive maintenance.

. Team member chosen to lead startup, construction, equipment choice,

staffing, training, equipment try out, and production of new Stamping

and Weld Assembly facility.

. Facilitated turnaround of assembly line 2 bus production through

enforcement of work rules, sped line up 15% thereby reducing the need

for OT by incorporating labor saving devices which in turn allowed for

10% reduction of line staffing.

Gayston Corporation - Springboro Ohio June 1988 - May 1993

Stamping, machining, assembly, and fabrication of aluminum & steel extruded

automotive & military parts as well as continuous process and batch

production of plastic injected molded parts for both US DOD and automotive

tier 1 suppliers and OEMs.

Engineer / Lead Production Supervisor

Directed four supervisors and 120 employees in all areas of production,

safety, and quality control. Communicated with senior management regarding

daily production concerns in stamping, injection molding, CNC machining and

fabrication areas. Controlled schedule, cost staffing, quality, and

production in stamping, injection molding, and machining areas. Worked with

support departments on process improvements in all production areas.

. Collaborated with support departments on the design, try-out, and

purchase of new tooling to launch $25M extruded Air Bag Inflator Body

product line.

. Oversaw introduction of new machining centers that increased

productivity by 40%.

. Saved approximately $500K in shipping costs and increased on-time

deliveries by assisting in negotiating lease of company trucks and

training and certifying employees as drivers.

. Contributed to growing the business from $20M per year to $60M per

year through raised efficiencies and a "Zero Defect" mindset.

. Initiated program to catalog and track use and life of stamping

tooling, injection molding tooling, and machining tooling that saved

the company $100K in tooling costs within the first year.

EDUCATION AND TRAINING

. B.S. Mechanical Engineering Degree - Wright State University

. "7 Habits of Highly Effective People" Franklin Covey

. Link Systems Course - OHSA requirements for Mechanical Power Presses

. Climate for Performance

. Interpersonal Management, DDI

. Several Lean Manufacturing and 5S training seminars sponsored through

International Truck & Engine Corp.

. Demand Point Lean Manufacturing training, experience in Six-Sigma, TPS

training

. TS 16949/QS 9001 and ISO 14001

. Very experienced in Microsoft Office including, Excel, Access, Power

Point, Word etc

. Attended many seminars and training classes on Human Resources law,

Union awareness and avoidance, FMLA, OSHA rules and enforcement etc.

AFFILIATIONS

Member, Society of Manufacturing Engineers

REFERENCES

Available upon request

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