Manager Six Sigma

Randall L. Norris

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

Altoona, PA 16602

Home: 814-***-**** *******@***.*** Cell: 814-***-****

Career Summary

Diligent, organized Plant and Operations Manager with extensive experience

implementing Lean manufacturing principles and programs. Strong business

and financial acumen, mechanical aptitude and the ability to identify,

analyze, quantify and implement "Key Performance Indicators" (KPI's) that

translate to positive EBIT management and results. Experienced leader who

builds strong teams and interacts equally well with all levels within an

organization as well as external customers and suppliers. Continuous

Improvement champion with exemplary work ethic and a track record of

improving the bottom line.

professional experience

Lumax Industries 2010 - Present

Plant Manager, Altoona, PA

Responsible for the operation of a 250,000 square foot, privately held,

lighting manufacturing facility. Reporting directly to the owner, this is a

"turn around" project. I have been tasked with assessing the current

operation and implementing changes to staffing, tooling, and processes with

the objective to cost effectively improve EBITA. Key immediate projects

include:

. Initiated process improvement teams.

. Restructuring inventory control systems.

. Implementing MRP and Master Scheduling modules.

. Updating Bills of Materials, routings, and rates to enable improved

standard costing.

. Identification of cost savings opportunities.

. Identify and pursue waste reduction opportunities.

. Implementation of a structured quality process.

MeadWestvaco 1988 - 2010

Operations Manager, Alexandria, PA 2006 - 2010

Responsible for the operations of 700K square foot manufacturing facility

with 370 full-time bargaining unit employees and 100 seasonal part-time and

/ or temporary employees. Held full financial responsibility for all

aspects of operations; SAP experience. Developed annual $125 Million

manufacturing operating budget and $5 million distribution center operating

budget.

. Initiated, implemented and sustained Six Sigma Lean Manufacturing

program; effectively managed program to break-even point in 3 years with

2010 savings projected to outpace cost of program.

. Logged and completed over 1200 Kaizan events.

. Led the Strategy Team in establishing Lean Manufacturing Principles

leading to year over year improvements of 8.6% reduction in total

manufacturing cost, 28% reduction in days of raw material inventory on

hand, 34% reduction in overtime and 16% reduction in production waste.

. Implemented extensive new internal reporting measures resulting in

significantly improved visibility of current departmental performance

versus budget and prior year metrics aiding in the achievement of plant

productivity improvements.

. Implemented / utilized Root Cause and Trend analysis (5Y / Fishbone) for

focused initiatives.

. Slashed manufacturing operating costs 26% in less than 3 years, a savings

of $3.6M / year and reduced gross waste by 1.5% ($600K) in 2 years.

. Achieved a 10%+ productivity / capacity improvement by improving machine

efficiency, change efficiency and increasing up time.

. Created and deployed new organizational structure for Safety Program,

using Behavioral Based Sciences (BBS), which reduced Workers Compensation

costs from 42 to 16 per labor hour worked in less than 3 years.

MeadWestvaco (Continued)

. Mentored management team, including three Six Sigma Black Belts,

continuously encouraging and overseeing the development of both technical

and managerial skills.

. Integral part of team that negotiated contract with United Steel Workers

union; responsible for operational language.

. Reduced defective parts per million from 660 in 2008 to 343 in 1 year.

. Transferred to this facility after consulting company's inability to

effectively implement lean manufacturing principles.

Operations Manager, Sidney, NY 2004 - 2006

Responsible for the operations 750K square foot manufacturing facility with

600 full-time bargaining unit employees and 200 seasonal part-time and / or

temporary employees. Held full financial responsibility for all aspects of

operations; SAP experience.

. Selected as member of the Sidney Innovation Team and company

representative for the operational language portion of the contract

negotiation team (Negotiated contract with Communication Workers of

America).

. Developed and conducted a Hazard Recognition training program for all

personnel that was later rolled out to the entire division.

. Reduced Total Case Incident Rate (TCIR) by approximately 27%.

. Embraced Six Sigma Lean Manufacturing initiatives and gained complete buy-

in by training associates. Established organizational chart for "Lean"

process (Executive Champion - Teams).

. Named to the MCOP Manufacturing Excellence Team.

Plant Superintendent, Williamsburg, PA 1990 - 2004

Responsible for operations of 320K square foot printing and converting

facility with 235 full-time employees operating on a continuous (24/7)

schedule. Specifically responsible for all necessary training programs

associated with manufacturing quality, safety and technical skill

improvements.

. Successfully implemented ISO9001 program with annual certification audits

performed by UL.

. Received "Quality Excellence Award" 1995 - 2002 with credits averaging

less than .01% of sales.

. Ranked #1 out of 8 plants in every measurable category for 9 years

running, due to effective analysis of operations and implementation of

best practices.

. Received Division Safety Excellence Award, 1994 - 2001 and Division

Performance Excellence Award, 1993 (finalist for award, 1997, 2000).

. Applied "Continuous Improvement" tools to assist suppliers, at their

request, with material / service improvements which assured receipt of

products that met specifications.

. Developed extensive knowledge of Human Resource requirements such as

FMLA, ADA, EEOC and recruiting / hiring practices.

Education, Training and Certifications

. BS, Human Resource Management, Geneva College, Beaver Falls, PA

. AS, Mechanical Engineering Technology, Pennsylvania State University,

Altoona, PA

. Certified Lean / Six Sigma Leader, Rochester Institute of Technology,

Rochester, NY

Experienced in

- SMED - Single Minute Exchange of Dies (Set-up Reduction)

- Poke Yoke - Mistake proofing

- TPM - Total Productive Maintenance

- Kanban - Raw Material / WIP inventory management

- Standard Work - Documentation of process / tasks "Best Practices"

- 5-S - Sort, Shine, Set in order, Standardize, Sustain

- Safety - Incorporate "Lean" tools and processes into safety culture

- Operating Equipment Efficiency (OEE)

- Value Stream and Process Mapping

. Project Management coursework, George Washington University, Washington,

DC

. Continuous Improvement Training Certificate, Pennsylvania State

University, Altoona, PA

. ISO internal auditor certification

. OSHA 10 and 30 hour certificates in General Industry Safety and Health

. Dupont Safety Training Observation Program (STOP)

. MWV Leadership Training / MWV Creativity and Innovation Training

. Mastery of Communication

. Statistical Process Control Training (SPC)

. Non Destructive Testing (NDT) Level II (Die penetrate, magnetic particle)

- initial certification achieved

. Extensive military training (all certificates available for review)

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