Manager Plant

Michael A. Roberts

**** *. ***** **., *******, MI 48118 734-***-**** cell (734)358-

**** abl8mv@r.postjobfree.com

OPERATIONS/Lean Leadership/INDUSTRIAL ENGINEER

P&L Responsibility/Lean Manufacturing/Leadership of

Accountable Teams/Continuous Improvement/

Measured Performance Focus/Plant Start-up/Results Driven

Education: Bachelor of Science, Industrial Engineering

Western Michigan University 1982

Certificates: Six Sigma - Green Belt; Kepner Trego Problem Solving; DuPont

Safety, JCMS Lean Manufacturing, Leadership Zenger-Miller, Kerzner Program

Management and Kaizen - The Kaizen Institute.

ReCellular Corporation - Operations - Dexter, MI 10/08 - 4/10. Electronics

sustainability firm . Developed business niche for refurbished accessories

with sales at $80K /mnth. Established partnership with vocational service

reclaiming 100,000 travel chargers annually. Member of lean initiative

team implementing plant wide 5S, and daily report out of key performance

measurables.

High-Tech Packaging - Lean Mfg Manager - Toledo, Ohio 12/07 - 5/08.

Contract packager for GM and DCX. Implemented 1 pc flow plant wide,

productivity reporting, and relayout of the plant to eliminate non-value

added tasks. These improvements resulted in a $60K/ mnth cost savings and

the elimination of second shift. Overall cost reductions exceeded $700K

annually.

Creative Foam Corporation - Mfg Engr (contract) - Fenton,MI 10/07 - 12/07.

Manufacturer of cellular and non-cellular foam for the automotive market.

Identified and eliminated non-value added tasks that improved current labor

variance by $20K/mnth. Audited and revised direct labor standards in the

molding department. Instituted productivity reporting plant wide resulting

in a 15% gain.

Alliance Interiors, LLC - Launch Manager (contract) - Lansing, MI 11/06 -

9/07. JIT sequenced parts delivery of acoustic components and carpeting

for GM Lamda vehicle. Responsible for plant launch including employee

safety, on-time delivery, and plant profitability. Established OEE

reporting, 5S/lean practices, preventative maintenance. Measured

performance first 6 months: 2 recordable accidents, $800K annual cost

reductions, OEE 82%, premium freight < $1K, avg. labor eff. >90%.

Johnson Controls, Inc. - Operations Director - Interiors Group 5/05 - 7/06:

Multiple plant assignment - Belleville, MI (Teamsters), Lakeshore, ONT

(CAW). Just in Time, sequenced part delivery of OHS, door panels, and

decorative trim. Achievements: Utilized Lean manufacturing/5S principles

and Six Sigma initiative to reach annual cost reduction goals in excess $1

million at both plants. Reduced safety incidence rate to zero lost time

accidents and 2 recordables annually. The Bellville plant closed without

degradation to quality and delivery performance on July 15, 2006.

Johnson Controls, Inc. - Engineering Director - Soft Trim - Plymouth, MI

4/02 - 5/05: Responsible for the design, prototype development and release

of all seating soft trim used in North America. Managed staff of 118 trim

engineers/technicians and budget of $20 million. Achievements:

Reorganized group from decentralized customer business unit format to

centralized functional group. Implemented 2-D gerber CAD process,

automated cutting, centralized purchasing activity and disciplined release

process. Reduced development time from 22 weeks to 7 weeks. Reduced

premium freight from $5.0 million/yr to less than $.25 million/yr.

Championed Six-Sigma transactional project - created standards and monthly

control charts.

Johnson Controls, Inc. - Engineering Director - Prototype Operations -

Plymouth, MI 4/00-4/02.: Responsible for component procurement, part

fabrication, and prototype assembly for Toyota, Honda, Nissan, GM, Ford and

DCX seating programs. Managed 80 engineering & technical employees with a

department budget of $70 million. Achievements: Created centralized

prototype purchasing department and reduced the number of metal fabrication

suppliers from 14 to 3. Established work center responsible for "Design

for Assembly evaluation" to eliminate retools at launch. These

improvements resulted in a cost reduction of $8.0 million/year.

Johnson Controls, Inc. - Plant Manager (Start-up) - Taylor, MI 5/91-4/00:

Just in Time, sequenced parts delivery of Jeep Grand Cherokee, Cherokee,

and Wrangler car seat sets. Responsible for plant profitability, employee

morale, customer satisfaction and all department functions of the

operation. Managed 500 employees on 3 shifts. D/L to I/L plus Salary

ratio 7 to 1. Achievements: Received Chrysler's Pentastar and JCI's

Chairman's Award for plant launch in 1992. Mentored 4 employees into Plt

Mgr positions. Exceeded cost reduction and plant profitability targets 6

of the 8 years at the plant under my leadership. Maintained union free

status.

Johnson Controls, Inc. - Program Manager - Plymouth, MI 3/89-5/91: 1992

M/Y Jeep Grand Cherokee Seating Program. Responsible for the program

timing, profitability, tooling, APQP activity, Supplier PPAP, site

selection, capital equipment procurement, plant layout, and plant staffing.

Achievement: This program launched on time, under budget, and was

profitable after 3 months in production.

Johnson Controls, Inc. - Operations Manger (Start-up) - Sycamore, IL 8/87-

3/89: Just in Time, sequenced parts delivery of Chrysler C-body car seats.

Responsibilities included the plant layout, capital equipment procurement

and daily production/delivery.

Hoover Universal/Johnson Controls, Inc. 6/81- 8/87: Industrial Engineer

(Start-up) - Lapeer, MI 3/84 -8/87: Just in Time, sequenced parts delivery

of Chrysler H-body car seats. Industrial Engineer - Corporate Office, Ann

Arbor, MI 6/81-3/84

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