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Manager Sales

Du Bois, Pennsylvania, 15801, United States
May 28, 2010

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Wayne A. Marhelski **** 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


Margin / Profit Improvement Due Diligence / Acquisition Integration



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


. 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


. 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%.


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


. 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


. Re-designed assembly lines with efficiency improvements in excess of

35%, and 48% reduction in defects.


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.


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


. 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


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)

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