Wayne A. Marhelski
abmqw9@r.postjobfree.com **** Treasure Lake 814-***-****
DuBois, PA 15801
Senior Operating Executive and transformational leader with P&L experience
of multi-site manufacturing operations with annual revenues in excess of
$65 million. Proven results in generating double-digit improvements in both
EBITDA and Cash Flow through the application of operational excellence.
Expert level knowledge of, and ability to apply, Lean Manufacturing (TPS)
concepts; as evidenced by multiple invitations to present at conferences
and professional society meetings. Key Qualifications include:
P&L Management Lean Manufacturing
Multi-site Operations International Sourcing & Supply Chain
Management
Margin / Profit Improvement Due Diligence / Acquisition Integration
PROFESSIONAL EXPERIENCE
SENSUS; DuBois, PA
VP of Global Sourcing & Logistics (June 2009 - Present)
Global responsibility for the sourcing and purchasing of raw materials and
components, with emphasis on sourcing from low-cost countries (China,
India, Vietnam, etc). Provide operational support to manufacturing facility
in Beijing, China; and Lean expertise to supplier base.
. Reduced material costs (as a % of sales) from 52% to 43.5% within 18
months.
. Implemented Lean principles in Sensus' Beijing, China facility;
increasing throughput by 20% with zero increase in labor requirements.
. Negotiated strategic contracts with vendors to provide consignment
services domestically and internationally to the DuBois facility which
resulted in average monthly inventory being reduced by more than $1.8
million.
. Developed relationships with Chinese government officials in key
economic regions as plans for a WFOE (Wholly Foreign Owned Enterprise)
are being developed.
VP of Operations, North America (February 2008 - June 2009)
P&L Responsibility for the Gas Division of a Private Equity owned business,
with >$65 million in sales and more than 280 employees. Spearheaded
adoption of Lean Manufacturing practices to improve cost structure, on-time-
delivery to customer and product quality which has resulted in growing
market share.
. Grew EBITDA by 20% through an improved operational structure, Lean
manufacturing processes and reduced material costs; even though sales
were down by 8% due to economic conditions.
. More than doubled cash flow (from $3,980k to $8,039k) over previous
fiscal year with reduced sales through improved operating controls,
enhanced supply chain strategy and lean initiatives.
. Reduced lead time to customers by 60% while increasing order
fulfillment rate by 50%.
OLES ENVELOPE; Baltimore, MD
Director of Operations (February 2007 - January 2008)
P&L responsibility for a 24hr/6-day high-speed printing operation with
sales in excess of $32 million annually. Directed facility toward the goal
of becoming a world-class envelope manufacturer through the application of
Lean Manufacturing and TPM (Total Productive Maintenance). Instructed and
led the executive team in the understanding and implementation of Lean
Manufacturing principles.
. Reduced downtime and indirect labor by >28% by reducing the time to
changeover machines.
U.S. BOILER; Lancaster, PA
Manager of Continuous Improvement & Quality (July 2004 - February 2007)
Acted as internal consultant for a 100 year old company with over $200
million in annual sales. Provided leadership and support to the operations
of five facilities and multiple divisions within the corporation. Designed
layouts and processes for Greenfield distribution and manufacturing sites
built around a Lean Manufacturing system; managed transition into these
facilities. Directed management and supervisors in the application of newly
installed methods and processes.
. Savings in excess of $5 million from reduction of finished goods
inventory levels while increasing on-time delivery to > 93% (a 15%
improvement) in one year.
. First year reduction of work-in-progress (WIP) in excess of $2
million.
. Reduced annual direct labor costs by $525k+ through improved
processes, material flow and accountability.
. Coordinated with local Workforce Investment Board center as part of a
consortium to apply for, and receive a state training grant of
approximately $650,000.
DIEBOLD; Danville, VA
Quality / Manufacturing Engineering Manager (January 2004 - July 2004)
Managed quality and improvement initiatives in a manufacturing division of
a $3.2 billion dollar corporation. Worked on corporate program to develop
universal manufacturing/quality metrics for entire company. Interfaced with
divisions and suppliers throughout the world: Asia, Europe, North and South
America.
. Re-designed assembly lines with efficiency improvements in excess of
35%, and 48% reduction in defects.
TRIUMPH BOATS; Durham, NC
Manufacturing Engineer (March 2001 - November 2003)
Employed to control and improve all new and existing processes. Responsible
for the introduction and application of Six Sigma and Lean Manufacturing
methods in a facility producing rotationally molded boats.
. Reduced annual overtime requirements by 84% or $230,000 annually,
through an increase in First-Pass Yield by more than 50%.
. Reduced annual material consumption of plastic by > $470,000.
CLAIREMONT ELECTRONICS; Yanceyville, NC
Manager of Operations & Engineering (May 1997 - February 2001)
P&L responsibility of a contract manufacturing company with sales in excess
of $30 million annually that serviced multiple industries (telecom,
defense, automotive and consumer goods). Directly supported two
manufacturing facilities and corporate office; performing operational
assessments, operational due diligence and training on lean manufacturing
practices.
. Negotiated a strategic partnership with a contract manufacturer in
Taiwan to provide high volume units for resale in the U.S. Contributed
over $3 million in sales annually.
. Grew EBITDA by > 12% annually through additional business won based on
quality, the ability to provide quick turnarounds on orders and
improved operations.
. Involved in the acquisition of two manufacturing sites (Florida &
Mexico). Designed layout of the Mexico facility.
ECA; Smithfield, NC
Business Unit Manager / Manufacturing Engineer (July 1993 - April 1997)
Lead engineer on quality and manufacturing processes in a start-up business
unit (promoted to Business Unit Manager in September '94).
. Grew sales to more than $12 million annually, servicing a global
customer base in the telecom industry.
. Delivered over $1 million in savings annually to the company through
the application of Lean Manufacturing.
. Designated as company-wide trainer (three facilities) on Lean
Manufacturing
United States Air Force (June 1988 - June 1992)
EDUCATION: MBA (Accounting & Finance); University of Liverpool
BS in Electrical Engineering; Kennedy-Western University
Certified Lean Manager; Ohio State University / Productivity Inc.
joint program
Certified Supply Chain Professional, APICS (The Association for
Operations Management)
Six Sigma Black Belt; University of Michigan, College of Engineering
Pennsylvania State University; University Park, PA
University of Maryland; Yokota AB, Japan
MEMBERSHIP: The Association for Corporate Growth (ACG)
The Association for Operations Management (APICS)