Injection Molding Manager

Bernard B. Carlisle

P.O. Box #* Cell 559-***-****

Senecaville, OH 43780

************@*****.***

SUMMARY

Achieved significant bottom line results, manufacturing cost reductions,

injection molding, blow mold, extrusion equipment and performance

improvements, processing commercial and engineering resins, high speed/high

volume, mold cavitation improvements, machine performance improvements,

machine and facility productive maintenance improvements, scrap reduction,

process improvements, develop/execute cost controls, implemented numerous

product quality improvements, drives continuous improvement.

EXPERIENCE

Jet Plastica Industries, Fowler, CA 5/02 -

5/08

Plant Manager

Increased capacity (30%) and redeveloped Western extrusion/injection

molding division. (disposable cutlery and straws) Directed performance

turnaround of high speed, high volume, injection molding MFG (Philadelphia

facility) with 47 injection machines, 24/7. Improved safety, quality and

output from 17.7 cs/dl to 32.7cs/dl. Improved division Food Related HACCP

scores, product quality and safety.

. Reduced direct and indirect labor with productivity gains of 50%

. Improved output with focus on manufacturing disciplines and GMP's

. Completed numerous capital cost reduction projects at ($250k

savings annually)

. Improved employee safety, developed systems and facility

improvements

. Improved product quality and output with mold and machine

improvements

. Improved equipment reliability with Productive Maintenance and

CMMS.

. Developed and implemented scrap recovery process.

Lear Corporation, Lebanon, VA 1/00 - 8/00

Facilities/Maintenance Manager

Facilitated $14mm Facility (Lean) restructure and expansion (automotive

door panels). Implemented MP2, maintenance management system and annual

training agenda. Rebuilt molding machines, reduced machine downtime,

installed new equipment.

. Redesigned facility to eliminate waste of materials movement

. Relocated all primary and secondary manufacturing equipment

. Participated in company Six-Sigma development program

. Built 10,000 sq. ft. expansion

. Implemented CMMS and preventive maintenance program

Tamor Corporation, Chicago, IL 8/98 - 4/99

Director of Operations

Planned and executed seamless transition of acquired product line(s)

(rolling storage carts)

between Tenex and Tamor. Renovated existing facility with 32 new and used

injection molding machines. ($10mm) Built 100,000 sq. ft. warehouse to

existing 180,000 sq. ft. manufacturing center. Implemented cellular

manufacturing to Rolling Storage Product line. Hired operations staff to

manage 280,000 sq. ft. facility 24/7.

. Reduced budgeted workforce 25% by incorporating work cells.

. Incorporated SPC, Kanban, cycle counting, GMP's

. Established labor and raw material cost controls

Zeta Consumer Products Corp. Kingman, AZ 2/97 -

7/98

Plant Manager

Directed plant turnaround. (Housewares) 750k sq. ft. facility with 28

injection and 3 large blow mold machines, 350 to 1500 tons, 24/7.

Implemented productive maintenance, safety motivational programs, quality

assurance and inventory cycle counting.

. Established labor and raw material cost controls.

. Implemented quality assurance process and personnel.

. Implemented workplace disciplines, GMP's and OSHA compliance.

Ekco Consumer Plastics, Inc. Phoenix, AZ 3/93 -

1/97

Plant Manager

Built 100,000 sq. ft. State-of-the-Art, Housewares' manufacturing facility.

($6mm) Selection and purchase of primary and secondary equipment.

Established and maintained annual zero based budget to achieve established

margins.

. Completed building ahead of schedule and under budget.

. Selected, hired and developed staff to manage 24/7 operations (8

direct reports)

. Shipped customer orders 99% complete and on-time (4 years).

. Established quality SPC program and GMP's with all employees.

. Developed safety motivational programs and cross-trained all MFG

personnel.

Rubbermaid, Inc. Goodyear, AZ 12/88 - 2/93

Technical Manager

Developed technical and maintenance personnel (5 direct, 60 indirect

reports) to effectively manage 390k sq. ft. facility, 24/7, world class

injection molding. Increased capacity from 17 to 27 machines. Rebuilt and

modified blow molding machinery for efficiency gains and scrap reduction.

. Directed material usage improvements to achieve 120% positive

varience.

. Directed projects to reduce scrap 50% and increase utilization 13%.

. Generated $700k annual cost savings with SPC, SMED and GMP's .

. Developed annual training programs to provide 80 hours per

technical employee.

Duracell, USA Cleveland, TN 5/86 - 12/88

Plastics Process Engineer

Started-up 24/7 injection molding operation to produce close tolerance

battery components. Installed and set-up machinery, performed process

start-up, troubleshooting and training for all manufacturing personnel.

Established quality inspection criteria, managed quality department,

developed specifications for process and plastic material selection.

. Improved utilization from 75% to 92%, reduced scrap from 7% to

0.5%.

. Developed mold/machine preventive maintenance procedures.

. Implemented product/process improvements to reduce product defects.

Pliant Plastics. Muskegon, MI 11/81 -

3/86

Plastics Manager

Managed custom injection molding operations with 18 machines, purchased

equipment, resins, colorants, performed r & d, process development, worked

with customers on new products from concept thru production. Implemented

technical training and quality controls lab.

. Consolidated vendors to reduce raw materials cost 17%.

. Injection molding processing, troubleshooting and process

efficiency.

. Started-up new tools, sampled new resins, provided technical

training.

. Performed mold/machine/maintenance, troubleshooting and cost

reductions.

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