Engineer Manager

THOMAS D. KU

**** *. ******** **

Chandler, AZ 85248

(949) 300- 9209 Cell

abmezi@r.postjobfree.com

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

____________________________________________________________________________

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OBJECTIVE Seeking a highly challenging Plant / Operations Management

position

EDUCATION Bachelor of Science Degree in Mechanical Engineering

California State Polytechnic University, Pomona

August 1984 - December 1987

Mechanical Engineering

California State University, Fullerton

1 June 1982 - June 1984

EXPERIENCE

Plant Manager

Tekni-plex Corporation (6/06 - 2/09)

Natvar (Division of Tekni-plex Corporation)

City of Industry, CA (5/08 to 2/09)

Transferred to the medical tubing division of Tekni-plex in a Plant Manager

capacity with multi-plant responsibility. This division is noted as a

leader in tubing extrusion technology for the medical and industrial

markets with annual sales of $60MM. Specialized tubing applications under a

Class 100,000 clean room are as follows; intravenous therapy,

cardiovascular procedures, urinary drainage and catheterization. Majority

of raw materials utilized are as follows; PVC, polyurethane, polystyrene

and ABS. Responsibilities include the direct management of 12 salary

personnel with a workforce of 130 hourly employees. Significant

accomplishments are as follows:

. $800M annual labor savings by reducing the temporary headcount from 40

to 20

. Extensively utilized KAIZEN to improve performance metrics

Overtime reduction by 15% >> $560M annual savings

Scrap improvement of 4% >> $72M annual savings

. Developed an operator training program to rapidly improve the operation

of the facility

. Developed an employee incentive program to promote forward thinking and

to improve the morale

Reduction of alcohol usage as a lubricant >> $24M annual savings

. Implemented the company's HR policy and procedures which was not enforced

. Developed committees (downtime, scrap, and safety) to create and

implement GMPs

. Initiated a profit margin analysis and systematically increased the Net

Sales per Pound in an effort to improve the EBITDA

Improvement of $.25/lb >> $180M annual sales increase

Plant Manager

Dolco Packaging (Division of Tekni-plex Corporation)

Fullerton, CA (6/06 - 5/08)

Ranked as the top 6th North American Thermoforming Corporation with annual

sales of $700MM. Products produced are polystyrene food packaging

containers serving the consumer, institutional, agricultural and food

service industries. Responsibilities include direct management of 10 salary

personnel with a workforce of 80 hourly employees. Significant

accomplishments include an annual EBITDA improvement of $800M for fiscal

07.

EBITDA improvement factors are as follows:

. New product offerings to expand to institutional product lines and

additional colors with higher contribution margins with a Net Sales

increase of $6.0MM. Machine loading capacity modeling was utilized to

analyze available capacity

. MANUFACTURING EXCELLENCE programs were introduced such as; KAIZEN EVENTS,

Process Improvement Teams, AIB, FDA, USDA, Performance Metrics tracking,

CPK tracking, Manning schedules & PM programs

. Process Improvement Team ( PIT ) includes the following:

Action items for all departments focusing on SIX SIGMA practices

Safety Committee and Monthly Audit development

AIB (American Institute of Baking) practice implementation

Changeover improvement

Scrap Reduction Committee

Employee Skill Matrix development and shift skill level balancing

Manufacturing Standard Line Condition (SLC) development

Gram weight reduction program implementation

SPC & cpk quality improvement implementation

Customer Service report tracking

Maintenance Work Order tracking implementation with OZ software

. Inventory reduction of $1.0MM with JIT manufacturing

. Resin consumption reduction with recycle introduction

. Competitive freight bidding resulting in an annual savings of $70M

. Roll stock inventory reduction from 500M lbs. to 200M lbs. with $270M

cash flow realization

Additional responsibilities include the following; P&L, Annual Reviews,

Wage Package reviews, Capital Expenditure reviews and Consolidated Monthly

Reports to corporate. Received a promotion on Nov of 07, as a Czar of Yield

Improvement, which includes additional responsibilities to improve the

yield across all 8 domestic facilities in lieu of current responsibilities.

Unit Manager

FDS Mfg

Pomona, CA (2/04 - 6/06)

Managed operations of the Protective Food Packaging Unit for a $50MM

private company manufacturing injection molded berry baskets, thermoformed

fruit clamshells, labeled clamshells and corrugated paper products

. Directly manage 3 of 4 departments with a seasonal average of 200+

employees

. Direct reports include Production Supervisors, Technicians, QC and

Maintenance Managers

. Personally handle all HR issues, hiring and termination

. Ensured OSHA compliance are met and maintained

. Ensure that product quality meets all required specs

. Utilized GMPs to develop metrics and monitor scrap rates

. Technical feedback to PVC sheet vendors in order to improve scrap rates

. Identify & reduce or eliminate major downtime causes utilizing KAIZEN

principles

. Execute monthly inventory cycle counts

. Developed weekly, monthly and quarterly PM schedules

. Developed process sheets in all departments to ensure repeatability

. Project manage the addition of a PET Sheet Extrusion department to

improve market competitiveness

. Research and develop additions of non-seasonal food service clamshells

with Marketing

Sr. Process Engineer/ West Coast Project Engineer

Pactiv Corporation

City of Industry, CA (4/00 - 2/04)

Senior Process Engineer responsibilities at a $2 Billion Dollar Protective

Food Packaging giant utilizing oriented polystyrene.

Significant accomplishments include : forming labor savings of 45

hrs/month, stock room supply savings

of $5.5M/year, scrap reduction of 8.76%, $1.5MM/year savings on

changeover reduction and uptime

increase of 6.03%

Promoted as the West Coast Project Engineer with an annual Capital

budget responsibility of $7MM

Promoted to manage the Maintenance Department prior

Resolved and implemented "Corrective Action Requests" (CARS)

KAIZEN utilized to improve changeover effectiveness (COE)

Troubleshoot daily issues in thin gauge thermoforming processes and

Irwin/Brown thermoformers

Heat balanced and developed standard line conditions (SLC ) for

thermoforming

Proved new molds with Cpk of 1.3 or better

Team leader in Energy Conservation Group, member of HACCP group and

Poly Variance group

Developed GMPs.from "Successfully Demonstrated Practices" (SDP's)

Directly supervised the thermoforming setup department mechanics in

accordance with the Union Contract

Supervised and directed 3 technicians in Labeling and Thermoforming

Departments

Technical support for production on a 24/7 basis

Ensured compliance are met; AIB, FDA & OSHA

Trained the technical group regarding new equipment setup, operation

and maintenance issues

Manufacturing Engineer / Production Manager

Intertrade Industries

Huntington Beach, CA (3/97 - 4/00)

Managed the operations of all phases of a plastic vacuum forming plant

specializing in heavy gauge plastics

Materials included ABS, HDPE, PVC, Lucite and styrene

Supervised the operation of 2nd and 3rd shifts in all phases of

production including quality inspections

Developed and implemented GMPs

Managed material inventory to support JIT production

Evaluated and quoted new products working directly with client

designers

Designed & fabricated CNC trimming and check fixtures

Programmed Thermwood CNC machines

Responsible for hiring and training new employees to maintain a

workforce of 60 employees

Directly responsible for all Customer Service interface (Clients

include: Star Trac, Boeing, Nokia and Ford)

Negotiated with plastic vendors in achieving volume pricing

Operations Manager / Manufacturing Engineer

Acrylia

Garden Grove, CA (12/92 - 3/97)

Responsible for all phases of establishing a new acrylic fabrication plant

with a workforce of 50 employees

Responsible for daily production of acrylic P.O.P. displays, fountains

and aquariums

Designed the plant layout to achieve maximum production efficiency

Designed a company website capable of accepting on-line orders and

custom quotes

Launched a marketing campaign targeting e-tailers, web surfers, retail

stores and distributors

Interfaced with clients regarding manufacturing feasibility and design

efficiency feedback

Responsible for all hiring and training of production personnel in the

art of plastic fabrication

Negotiated with plastic suppliers and LTL freighters on volume pricing

Responsible for all New Product Development from the design phase to

full production

Responsible for designing all product packaging

Manufacturing / Design Engineer

ASC Colamco

San Dimas, CA (2/88 - 11/92)

Design Engineer responsibilities at an Automotive and Trucking interior

manufacturing facility

Responsible for I.S.I.R. submittal and initial sample packages

Designed and produced prototype interior trims such as door panels,

dashboards, valances,

lambrequins for the automotive, RV and trucking industry

Involved in engineering liaison with the trucking, RV, fitness, and

healthcare industries

Coordinated heavily with production, QC, sales and purchasing

especially during new project

initiation phase

Evaluated capital expenditures and time studies to improve production

performance

Quoted new and existing products

Collaborated with tooling manufacturer in designing dies, fixtures and

jigs

Interfaced with supplier in sourcing new material applicability

Troubleshoot daily production problems

SKILLS CNC programming

Familiarity with Allen Bradley & Toshiba

drives, Allen Bradley PLC,TCS,

Ballerina software and AutoCad

PC & Mac literate with respective software

1 Y14.5, S.P.C., SAP, QAS, AS400

Speak fluent Korean and light Spanish

QC instruments, machine shop tools, equipment

and processes

Kaizen Events

Lean Manufacturing

KANBAN

AIB, FDA, ISO, OSHA

Contact this candidate