Manager Project

DAVID A. PATRICK

**** ********* ***** . *******, ** 33596 (H) 813-***-**** . (M) (813) 892-

1674

E-mail: abm69c@r.postjobfree.com

HIGH-IMPACT MANUFACTURING/CONTINUOUS IMPROVEMENT LEADER

Plant Manager, "Lean" Leader, Strategic Planner

Seasoned operations manager with Lean Manufacturing/Toyota Production

System implementation experience. Extensive background with productivity

and quality initiatives with P&L responsibility. Skilled in cost reduction

initiatives using lean manufacturing, productivity, and quality concepts

directly impacting the bottom line in terms of productivity, scrap, yield,

and claims savings. Recognized for effective leadership skills.

Areas of Expertise

? Manufacturing Management ? Lean (Toyota) Manufacturing

System ? Process Improvement

? Safety Leadership ? Best Practices

Deployment ? OEE Improvement

? Quality Systems ? Strategic Planning

? Change Management

? Plant Regulatory Compliance ? Problem Solving

? Employee Engagement

Key Accomplishments

. Lead implementation of cellular manufacturing in 5 plant locations

consisting of 17 fabrication areas and 7 of 14 service centers

resulting in productivity gains of over 15% valued at close to $1

million in annual savings

. Lead implementation of best practices for 6 manufacturing locations in

North America and 1 location in Europe resulting in cost reductions

valued at $4.5 million annually

. Implemented Lean Manufacturing / Process Improvement initiatives

resulting in 40% scrap reduction, 15% improvement in productivity and

reduced headcount by over 40 hourly and 7 salaried

. Lead "Lean" deployment resulting in turn-around from <$12 million> to

$10 million profit in one year. Plant was highlighted by Alcoa in

2000 annual report and received corporate award for best financial

improvement.

. Lead implementation of Lean Manufacturing resulting in annual cost

savings exceeding $15 million.

Professional Experience

ALCOA, INC. 1996 - Present

Kawneer Company (Alcoa, Inc.) Norcross, GA, 2008 to Present

Manufacturing Support Manager

Kawneer, a division of Alcoa, is $600 million global manufacturer of

commercial curtain wall systems with 5,000 employees. Lead the

implementation of best practices for 6 manufacturing locations in North

America and 1 location in Europe. My responsibilities included Best

Practice deployment in 8 extrusion areas, 6 paint systems, and 5 anodizing

areas as well as leading improvement activities in Fabrication in all

plants and 12 associated service centers.

. Interim Plant Manager from March 2006 to December 2006 for Springdale

Operations. A 350 employee curtain wall and window manufacturing

operation.

. Implemented Cellular Manufacturing practices in 5 plants and 7 of 14

service centers improving performance by as much as 45%

. Implemented Best Practices initiatives on Temperature Management and

Die Technology that helped improve output of the operations by 8%.

. Implemented Maintenance and Waste Management Best Practices reducing

downtime by 15%

. Implemented OEE tracking systems in all manufacturing locations

DAVID A. PATRICK 2606 Clareside Drive . Valrico, FL 33596 (H)

813-***-**** . (M) 479-***-****

. Lead 30 improvement / kaizen initiatives in manufacturing, finishing,

and fabrication areas that improved overall performance by 15 - 25%

Grottoes Plastics Plant, (Alcoa Inc), Grottoes, VA 2004 to 2006

Operations Manager

Grottoes Plastics Plant is a $500 million global manufacturer of Food,

Consumer and Industrial Plastics Packaging products. Lead manufacturing of

300,000 square foot operation including over 80 Hourly (Union) workers.

Manage 10 extruders for PVC, and 3 extruders for nylon, 2 automatic packing

lines, 6 blending operations and recycle area.

. Implemented Lean Manufacturing / Process Improvement initiatives.

Impact was scrap reduction of 40%, and 15% improvement in

productivity. Plant was able to reduce overall headcount by over 40

hourly and 7 salaried

. Achieved lowest OSHA recordable rate in plant's history. Recognized by

business unit as one of its safest plants

. Improved raw material yield to meet and exceed standard. Material

variances moved from <$100K> to $75K

. Implemented shipment consolidation to customer warehouse; reduced

cost, improved on time delivery by 18%

Alcoa Extruded Construction Products, (Alcoa, Inc), Plant City FL 1999 to

2004

Business Unit Alcoa Business Systems Manager (ABS Manager)

AECP is $1.2 billion multi site extrusion operations supplying aluminum

extrusions to the building and construction industry. I lead the

implementation of Lean Manufacturing (Alcoa Business System or ABS) in 7

extrusion plants.

. From 2002 through 2004 was the Operation Manager for REDD Team

Manufacturing, one of the Alcoa acquisitions. Developed 2 new

products utilizing cellular manufacturing processes that added $2

million profit with ROC of over 10%.

. Lead 2 model plant implementations with a 30% reduction in the

implementation cycle. The Model process was recognized at the 2001 ABS

Awards as best ABS deployment model

. Turned one plant around from losing $12M in profits to making $10M in

one year. As a result, implementation was recognized by Alcoa in 2000

ABS awards for the best financial improvement of any plant.

Alcoa Inc. Pittsburgh, PA 1996 to 1999

Specialist/ ABS Manager, Corporate Office ABS Group

Alcoa Inc. is a $24 billion supplier of aluminum products to aerospace,

automotive, and building and construction industry. I was one of the

original consultants for the ABS group lead the first ABS implementation.

. Lead turnaround of smelting plant with over 500 unionized employees.

Improved ROC to 8.5% from negative in nine months, reduced Inventory

by $3MM, reduced 50 full time equivalents and improved flow by 20%.

. Lead turnaround of Foil Plant with 450 unionized employees. Operation

improved from 2% ROC to 8.5% in six months, reduced inventory of

$2.5MM, reduced 75 full time equivalents and eliminated 15 salaried

positions.

. Completed four manufacturing analyses for smelting group globally with

impact on savings of over $30M. Logistic group at each location was

chartered with realizing savings. Results achieved over 3-year period.

PROUDFOOT, USA 1985 to 1996

Project Manager, West Palm Beach, FL

Proudfoot PLC is a $450 million global management consulting group

developed specializing in productivity and quality implementation

strategies for manufacturing, service, financial, and hotel industries.

. Lead Quality Improvement System implementations in manufacturing,

service and hotel industries.

. Implemented cellular manufacturing concepts. Freed up over 500,000

square foot of warehouse space and reduced finished goods inventory by

over $1M in one automotive supplier.

. Reduced lead times by 50% in major aerospace operations. Reduced order

entry from 14 to 2 days. Flow on floor was simplified to allow high

volume orders to flow through shop in 5 days.

Education and Certifications

BS in Business Administration, Indiana University of Pennsylvania, Indiana,

PA

Masters in Business, University of Phoenix, Phoenix, AZ

DAVID A. PATRICK 2606 Clareside Drive . Valrico, FL 33596 (H)

813-***-**** . (M) 479-***-****

CERTIFICATIONS:

Kawneer Leadership, ABS Leadership, Lean Implementation, Process Mapping,

Arvin TQP System, TQM, QIPM, QES, and QWG, Management Change, Facilitation

and Team Building, Lead Auditor Training (ISO & QS 9000)

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