Plant Manager

Eric S. Fulcher

***** ***** & Park Road +** **(*) 6336 7118

St. Louis, MO 63126 abmo35@r.postjobfree.com

CAREER OBJECTIVE

A career in which I promote Safety, Quality, Delivery, Cost, Morale, and

Environment principles in a lean manufacturing setting. To lead a mass

production organization in it's transition to lean through proven abilities

to:

. Inspire a healthy work force to boost productivity levels and save on

short/long term medical costs.

. Take quality to a six-sigma level.

. Reduce lead times to the end customer and reduce plant dock-to-dock

times.

. Shift the focus from Labor & Over-Head to Total Cost Analysis.

. Boost Morale - Promote a safe & fun work environment where employees want

to come to work in a family setting.

. Instill disciplined growth through the basics and sticking to a game

plan.

QUALIFICATIONS

A dynamic, results-driven, pioneering professional with 17+ years

experience in:

Six Sigma - Green Belt Lean Manufacturing Total P&L Responsibility

Certified

Problem Solving Interviewing / Hiring International Operations

Coaching / Mentoring Industrial Strategic Team Development

Planning

Budgets & Forecasting Supplier Relations Lead-Time Reduction

Total Productive Customer Satisfaction Variability Reduction

Maintenance Leadership

JIT Delivery & Arrival / High Volume Assembly Statistical Process

SMF Control

PROFESSIONAL EXPERIENCE

Faurecia Group - Nanterre, FRANCE 2005 -

Present

Industrial & Quality Director ASIA - Seoul, KOREA 2009 - Present

Responsible for all aspects of Industrial (Operations / HS&E / ME / Lean

manufacturing) and Quality functions for the Asia Division for Faurecia

Emission Control Technologies. We have two manufacturing plants in KOREA

+ eight plants in CHINA + one plant in THAILAND. Full P&L Responsible.

Plant Director - Silao, Guanajuato, MEXICO 2006 - 2009

Responsible for site-selection study to support customer footprint

evolution; secured funding from parent company in France; constructed new

220,000 sq.ft. facility in 7 months - groundbreaking to SOP; transferred 8

programs under current production to new facility with no interruption to

the Customers. Full P&L Responsible.

Director of Manufacturing Engineering - Toledo, OH 2005 - 2006

Provide leadership to AME Engineering Supervisors & Plant Manufacturing

Engineering Managers in standardization direction and design. Set

corporate Footprint and Industrial Manufacturing Strategy for high volume

exhaust systems, Component & JIT plant equipment & tooling standards and

goals. Developed internal Process Control System architecture with EMP &

SPC loads. Lead Process Capability teams for reduction of manufacturing

variation. Full Budgetary / P&L Reaction Responsible.

Lear Corporation - Southfield, MI

Director of Advanced Manufacturing Engineering - Madison Heights, MI

2004 - 2005

Provide leadership to AME Engineering Supervisors & Plant Facility

Managers in standardization direction and design. Set corporate JIT Plant

equipment & tooling standards and goals. Develop internal Process Control

System architecture with EMP & SPC loads. Lead VRT teams for reduction of

manufacturing variation causing field warranty. Full Budgetary

Responsible.

Regional Plant Facilities / Operations Manager 2002 - 2004

Provided leadership to JIT Seating Plant Facility & Operations Managers in

new business start-ups and continuous improvement activities. Lead

equipment suppliers in standardization and cost reduction techniques.

Ford Motor Company - St. Louis, MO

Final Area Production Manager - Trim & Chassis 2000 - 2002

Provided leadership to Manufacturing Planning Specialists and Production

Supervisors in final assembly of Explorer vehicle line. Led VRT teams for

reduction of field warranty in electrical and interior trim.

Paint Superintendent - Paint Department 2000

Provided leadership in sealer and paint applications for Manufacturing

Planning Specialists and Production Supervisors. Led VRT teams for

reduction of field warranty in paint and chip & scratch.

Eric S. Fulcher Page 2

DaimlerChrysler Corporation -

Manufacturing Engineering Manager - Paint Department, St. Louis, MO

1998 - 2000

Controls Engineer - Paint & Energy Management, Auburn Hills, MI 1997 -

1998

Automation / Maintenance Supervisor - Paint Department, Sterling Heights,

MI 1993 - 1997

U.S. Marine Corps - USA

Electrician/Aviation Radio Technician 1986 - 1990

Education

Masters of Science Systems Engineering (28/32 hours completed) - Oakland

University

Bachelor of Science Electrical Engineering - Oakland University

Associate of Science Engineering - Bay de Noc Community College

Associate of Applied Science Industrial Electronics - Bay de Noc Community

College

Certificate of Industrial Electronics - State of Michigan

Selected Achievements

Created & Implemented Industrial Strategy for Faurecia Exhaust Systems -

NAO.

. Analyzed and constructed the PMT (Plan Mid-Term) for FES-NAO Industrial

Strategy in support of the Customer evolutions and cost-structure

required in order to continue to stay competitive and win future

business. Executed the LCC (Low Cost Country) portion of the strategy by

building two new plants in Mexico, relocating existing production lines,

launching new production lines and closing of out-dated factories.

Created Lear Manufacturing System and Corporate Standardization Techniques

& Specifications.

. Foundation member for creation of Lear Corporation Manufacturing System

(LMS) and internal software design of control systems for expansion of

EMP & VRT reductions through lean manufacturing principles rooted from

TPS, COS & FPS. Result: Planned goal of 3 plants per year was exceeded

to 4 plants in first year.

Improved safety record of Trim Department.

. When promoted to Trim Superintendent the department's safety record was

9th in the corporation. Analyzed safety data, determined root causes,

assembled ergonomics committee, and implemented best solutions. Results:

Dropped severity rate from 103 to 42, lost time rate from 14.6 to 1.9.

Trim Department went from 9th to 1st position for lost time and severity

rates and 3rd overall for the corporation in safety during a new model

launch.

Lowered St. Louis Paint warranty claims to lowest level in ten years.

. The oldest paint shop in the Ford assembly plant line-up was only at 88%

FTT; warranty claims were averaging 9.1 R's per thousand. Brought the

process under control within six months of promotion to Paint

Superintendent. Results: Raised the FTT to 93% and was sending the

paint department home 30 minutes ahead of the rest of the plant ($1022

in labor and $3000 in materials) while dramatically decreasing warranty

claims (4.8 R's/1000).

Reduced assembly process manpower by 9% per shift over projections.

. Standard Book Time was projected at 274 workers per shift for the trim

assembly process. Assigned a team of Industrial Engineers to review MOST

Studies and work with Union MOST team. Result: Settled 96% of jobs in

90 days while reducing the manpower by 26 workers per shift.

Analyzed and resolved windshield breakage problem utilizing a Six-Sigma

approach.

. Trim was replacing windshield glass at a rate of 1-2% of glass decked

per/shift. I assembled a Greenbelt team, identified CTQ's, tracked,

analyzed, adjusted and found 2 major contributors - ditch sealer height &

skips in urethane. Result: Lowered replacement to < .1% for > 95% of

time.

Launched an FMVSS zero recall campaign for plant controllable items on the

new 2002 Explorer.

. Trim Department has the most Federal Motor Vehicle Safety Standards

items out of all the departments. My team and I designed and

implemented two strategies (DC electric nut runners for final torque's

and a redundant system check for reliability) to insure conformance to

standards. We monitored the data through the use of control points and

made changes accordingly. Result: At the end of the three-month ramp-up

period to full production, the systems were in place. To date there

have not been any plant controllable recall items from the St. Louis

Assembly Plant.

TECHNICAL SKILLS

PLCs, TS-16949, Work cell Robotics & Corporate

Mainframes, QS-9000, Design & Plant Automation Standardizatio

PCs & Software ISO-14001 Layout - PULL n / Technical

Systems Spec.'s

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