Manager Plant
Resume:
CONFIDENTIAL RESUME
JOHN D. (DON) BLEVINS
Monticello, KY 42633
March 31, 2010
SUMMARY:
Wood industry plant manager with an established record of making significant flow, safety, quality, delivery
and cost improvements. Successful experiences in team, non-union and union environments. Strong leader
who receives deep satisfaction from developing subordinates and leading plants to unprecedented
performance levels. Sound knowledge of solid, veneer and engineered wood processing to include finishing,
laminating and assembly.
WORK EXPERIENCE:
AMERICAN WOODMARK (February 2004-January 2010)
Plant Manager at Monticello, KY Plant (4 years) with 525 (currently 350) employees purchasing and drying
hardwood lumber and converting to kitchen cabinet doors, face frames and other components.
•Set company standard for lumber purchasing, grading and drying.
•Improved lumber yields and reduced scrap four consecutive years.
•Created a make to order shop with a minimum run size of one.
•Manufactured and shipped 90% of product on day order was received.
•Plant earned OSHA Sharps certification, worked 2.3 million hours w/o lost time accident.
•Plant received prestigious AWC president's award 2 out of 4 years.
Plant Manager at Hazard, KY Plant (7 months) with 330 employees purchasing and drying hardwood lumber
and converting it into dimension for kitchen cabinet components.
•Eliminated major production stoppages by correcting serious maintenance and equipment design issues.
•Increased output 20% with no cost penalty.
Plant Manager at Orange, VA Plant (14 months) with 285 employees purchasing and drying hardwood
lumber, and converting it into dimension for kitchen cabinet components.
•Reduced costs 10% or $1.7 million annually through yield, scrap and labor improvements.
O’SULLIVAN FURNITURE INDUSTRIES, South Boston, VA (July 1996-February 2004)
General Manager for 700-employee plant converting particle board and fiber board into RTA home and office
furniture products for national and regional retailers.
•Financially turned plant around from losing money to 20% pretax profit.
•Tripled production levels in plant over two year period peaking at $165 million annual sales.
•Successfully implemented $50 million in capital projects.
•Made plant a 24/7 operation.
•Through Lean reduced average process time and run sizes 50%.
•Reduced finished goods inventory 80%.
•Made waste stream revenue producing, saving $600,000 annually.
ATHENS FURNITURE INDUSTRIES, Athens, TN (January 1991-July 1996)
Director of Lumber Management (2-1/2 years) engaged in procuring, drying and processing $10 million of
lumber annually into furniture dimension components.
•Reduced total lumber cost 18% by improved purchasing and processing practices.
Plant Manager (3 years) for 200 employees producing curios and accent furniture products.
•Financially turned plant around after 10+ consecutive years of losing money.
•Used Cellular Manufacturing making plant capable of effectively producing a variety of products.
•Developed Best Practices training materials for all employees.
FRANKLIN FURNITURE, Greeneville, TN (July 1989-December 1990)
Director of Manufacturing for two plants with 260 employees producing early American dining room
furniture.
•Used Cellular Manufacturing enabling plant to effectively add two product categories.
•Reduced inventory 40% through improved controls.
•Reduced labor costs 15% through more efficient scheduling and asset utilization.
HON COMPANY DIVISION OF HON INDUSTRIES, Muscatine, IA (January 1984-July 1989)
General Manager (1 1/2 years), Louisburg, NC Plant with 175 employees producing wood veneer and paper
laminate office furniture.
•Totally changed product mix from high-end to medium priced office furniture.
•Developed and implemented new layout to accommodate the new product mix.
•Led plant to financial break even in 6 months.
Plant Manger (3 years), Oak Plant #2, Muscatine, IA with 165 employees producing high pressure and paper
laminate office furniture.
•Lead plant through 3 progressively more profitable years after 5 years of losses under previous manager.
•Switched all product to European fastening and assembly system with $800,000 annual savings.
•Introduced new products that allowed a 2 1/2-fold increase in sales.
•Increased product offering 5-fold with no increase in lead time to customers or reduction in inventory turns.
TRENDLINE FURNITURE, Hickory, NC (August 1978-December 1983)
Plant Manager (2) years, Superintendent (3 1/2 years) in a 100 person plant producing wood living room
furniture.
HAMMARY FURNITURE, Lenoir, NC (September 1971-August 1978)
Machining Supervisor. Served in this position for approximately (3) years after working in various positions
of increasing responsibility.
EDUCATION:
Appalachian State University, Boone, NC
BA Industrial Management, 1982
Caldwell Community College, Hudson, NC
AAS, Furniture Production, 1975
Completed numerous Lean, management and engineering seminars ranging from one day to two weeks in
length, 6 Sigma Green Belt
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