Manager Quality Assurance
Resume:
DOUGLAS W. SHANK
Ligonier, Indiana 46767
**********@********.***
SUMMARY
Management professional with proven expertise in efficiency gains,
trouble shooting, plant consolidation, and contract negotiations
with emphasis on the Toyota Production System.
EXPERIENCE
Bosch Rexroth, Buchanan MI 2008 to
Present
Distribution, warehousing, manufacturer of conveyor systems and
lean equipment.
Production Manager
. Managed $2.5 million budget to goal including labor, materials,
and equipment costs, for $40 million plant.
. Directed 3 lead operators, master scheduler, and 27 hourly
associates for assembly, machining, warehousing,
maintenance, and shipping.
. Reduced down time 25% by establishing visual production
management board.
. Increased efficiency 30% using lean line design to set up work
areas in one-piece flow.
. Eliminate 75% of the mobile equipment by developing milk run,
using Kaizen techniques.
. Justified capital equipment and established plant-wide one-piece
flow by developing vision as member of 3-person planning team.
. Achieved no lost time or recordable injuries for 2 years as
plant safety advocate.
Alcoa Inc. Auto and Truck Structures, Auburn IN
2005 to 2008
Extruded and fabricated aluminum shapes for automotive, commercial
truck and architectural markets.
Production Manager and Materials Manager
* Achieved 0 lost time accident as safety team leader responsible
for environmental, health, and safety.
* Directed 2 managers, 6 supervisors, master scheduler, logistics
supervisor, 14 lead operators, die shop, and 160 hourly
associates for assembly, machining, maintenance, and shipping.
* Managed $15 million budget including labor, materials, and
equipment costs, for $80 million plant.
* Reduced raw materials, work in process, and finished goods
inventory $750,000 by establishing plant-wide Toyota Production
System.
* Reduced costs $1.2 million per year by leading Kaizen events.
* Reduced WIP and inventory costs by implementing plant-wide
visual Kan Ban to level load scheduling, production, establish
production goals, and set audible "pace" (as taught by Yomo
Consulting Group).
* Achieved TS 16949 certification by implementing and documenting
quality and manufacturing processes.
Meridian Automotive Systems, Grabill IN 1999 to
2005
Producer, injection and SMC molded products for Ford, GM, Chrysler
and Mitsubishi.
Manufacturing Manager and Toyota Production System Coordinator
* Instituted plant-wide Toyota Production System; reduced overtime
50% by using takt time to set "pace" in 33% of the predicted
time.
* Saved $2.5 million (first year) and reduced labor 33% by using
Kaizen techniques.
* Directed 3 supervisors, 18 team leaders, and 200 hourly
associates in 3-shift operation including molding, assembly,
prime, and top coat.
* Improved quality (no rejects for 2 years) by using mistake
proofing techniques.
* Successful on time start up and launch for Ford Lincoln
Navigator program.
* Achieved QS 9000 and ISO 14001 certification as part of 8-person
team.
* Saved an average of $800 thousand in each of 13 plants as
internal lean consultant (as taught by Yomo Consulting Group).
EDUCATION
Indiana Wesleyan University, Marion IN
BS, Business Administration
Olney Central College, Olney IL
AAS, Welding and Metallurgical Technology
PROFESSIONAL DEVELOPMENT
TS 16949 Employee Involvement
CNC Machining
ISO 14001 Quality Assurance
Advanced Quality Planning
QS 9000 Toyota Production System
Lean Manufacturing
Kaizen Environmental
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