DOUGLAS W. SHANK

**** **** - *** *****

Ligonier, Indiana 46767

260-***-****

abjgix@r.postjobfree.com

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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