Manager Engineer
Resume:
Saint Johns, MI ***** Phone 989-***-****
E-mail **********@*****.*** Keith W. Sawyer
Objective Leadership position guiding an Operations/ Production team providing
the opportunity to employ the skills, abilities and expertise I have
Qualificatio gained and demonstrated through my education and career
ns accomplishments.
Demonstrated success in leading an organization at the plant level
through difficult business conditions while dramatically improving
safety, quality, reducing costs and maximizing productivity.
Expert ability to develop technical professionals into a cohesive unit
providing a strong foundation upon which operational excellence was
achieved.
Extensive knowledge and accomplishments in all aspects of operations
execution, budget preparation and management at the plant and corporate
levels.
Demonstrated abilities to effectively interact and communicate with
senior executive team members, all levels of management, production
personnel, customers and external vendors & contractors regarding all
aspects of a manufacturing environment.
Demonstrated ability and success in managing multiple responsibilities,
prioritizing key initiatives, and effectively developing strategies and
business plans necessary to address severe budgetary and business
challenges to the operations.
Professional August, 2008 - Present Ventra - Ionia, LLC, Ionia, MI (Became part of
experience FNG July 2009)
Facilities & Engineering Manager - Ionia Facility
Responsible for the development and oversight of a cohesive,
coordinated and effective Manufacturing Engineering Group of thirty
(30) professionals responsible for implementation of advanced
planning, equipment design and coordination of critical new program
launches for organization; providing design and development support for
cost and process improvement initiatives; development and
implementation of cost estimating for all future programs; facility
infrastructure, capital refurbishments and management; MRO Inventory
Management
Developed, implemented and managed strategic manufacturing plan leading
to the successful launch of the 2010 Ford Taurus Chrome Grille
assemblies in July 2009 meeting, and exceeding in some areas, Ford's
challenging build dates and requirements, as well as ensuring
compliance with Ventra's TS 19649 and Ford Q-1 rigorous procedures and
processes. Responsibilities included all processes, tooling and capital
requirement implementations.
Developed and managing strategic manufacturing plan to launch the Ford
2011 F250/350 Super Duty front grille assembly in January 2010.
Program has met all milestone dates and met or exceeded customer
expectations. Program will launch exceeding expected profit margins.
Responsibilities included all processes, tooling and capital
requirement implementations.
Developed and managing strategic manufacturing plan to launch the GMT
Super Duty Chevy/GMC/Denali front grille assemblies in April 2010.
Program has met all milestone dates and met or exceeded customer
expectations. Program will launch exceeding expected profit margins.
Developed plan and managed transfer of Current Dodge Ram Front bumper
program to Ionia from another FNG Facility in a (2) month time frame
without negative impact to Chrysler quality or delivery. Complete
September 2009.
Implemented and managed an Energy Reduction Team to effectively review
plant operations and develop cost reduction programs. 2008 to 2009
energy reduction savings in excess of $1.0 Million annually. Focus on
compressor usage, lighting effectiveness, HVAC systems, Boiler Systems
January, 2006 - August 2008 Meridian Automotive Systems, Ionia, MI
Plant Manager - Ionia Facility
Successfully developed and lead an effective and efficient Management
Team increasing performance in the areas of Safety, Quality and Cost
Improvement, achieving challenging organizational objectives and
targeted business performance metrics.
Achieved successful consistent record for reducing the level of
recordable incidents from 124 in 2005 to 77 in 2006 to 58 in 2007.
Successfully and repeatedly achieved superior results in exceeding
challenging business goals surpassing EBITDAR target of 19.2% achieving
20.3% in 2006 on Sales of $185 Million and again in 2007 exceeding goal
of 22.0% and achieving 23.7% on Sales of $181 Million. Superior results
achieved through the application of MBS Kaizen Events, strategic Labor
Management initiatives and significant process improvements.
Reduced overall Plant Inventory in 2006 and 2007 by over $5 million;
reduced raw material by $2million; reduced vital Nickel inventory by
176K lbs.
Achieved significant reduction in 2007 Overhead Costs reducing related
expensed by $8 million representing approximately 4% of Sales in 2007.
Responsible for leading strategic development and implementation of
Plastic Plating Process which made possible an additional $30 Million
in Sales for 2008.
October, 2003 - January, 2006 Meridian Automotive Systems Ionia,
MI
Industrial & Manufacturing Engineering Manager
Responsible for the development, implementation and oversight of a
cohesive, coordinated and effective Manufacturing Engineering Group of
fifteen (15) engineering professionals providing increased support for
cost and process improvement initiatives; implemented advanced
planning, equipment design and coordination of new program launches for
organization.
Successfully undertook responsibility for $7.0 million initiative
involving program and facilities equipment and related process
implementation, including overall management responsibility of internal
WIP rack fleets for all programs.
Designed and implemented multiple process improvements resulting in
over $900,000 annual savings for the organization in 2004.
Developed, implemented and managed strategic manufacturing plan leading
to the successfully launch of the 2004 F150 Ford front and rear bumper
assemblies meeting, and exceeding in some areas, Ford's challenging
build dates and requirements, as well as ensuring compliance with
Meridian's QS-9000 and Ford Q-1 rigorous procedures and processes.
Developed and implemented key cost estimating procedures for current
and future programs improving accuracy and timeliness of quotation
process for all divisions of FEM/REM involving Five (5) different
facilities
Responsible for actively managing Product Data Management (PDM) for
five (5) FEM/REM facilities, including routings, BOM's, production
standards, FMEA's, and plant capacities for future and current
programs.
June, 2000 - October, 2003 Meridian Automotive Systems Ionia, MI
Manager of Plant Engineering for Exterior Plastics
Responsible for providing lead process, facility and construction
engineering management of eleven (11) multi-million $ SMC molding
facilities with annual capital budgets: 2003 - $13.5 Million. 2002 -
$9 Million. 2001 - $8 Million. 2000 - $6.1 Million
Project Highlights
Designed, upgraded and relocated multi-million $ SMC (Sheet Molded
Compound) process to a refurbished facility in Grabill, IN - Complete
May 2003. Capital: Building - $2.5 Million, Process upgrades &
relocation - $3.9 Million.
Designed and implemented an ultraviolet coating system, including
upgraded paint system, meeting challenging GM specifications in
Grabill, IN Facility. Designed and implemented expedited startup
timeframe condensing it to five (5) months in order to meet customer's
required program timing. Complete - June 2003. Capital: $2.3 Million.
Undertook Salisbury, NC Plant expansion to meet customer needs;
implemented new plastic molding process to achieve customer material
specifications and improved facilities and environment. Complete -
November 2003. Capital: $5.6 Million
Relocated three (3) programs to three (3) new facilities from
Centralia, IL facility. Project completed within required timing
meeting three (3) customers' shipping requirements. Completed -
December 2002. Related capital expense: $800,000.
Oversaw construction of Celaya, Mexico SMC molding facility and
implementation of new SMC Molding Facility. Planned and coordinated
transfer of multiple programs for production. Coordinated purchase of
new and transfer of current equipment to meet timing and customer
needs. Coordinated installation of SMC prime paint line. 2000 through
2002.
Managed and coordinated Meridian Construction Group - Three (3)
salaried project supervisors and unionized hourly construction,
fabrication and mechanical crews assigned to projects throughout the
company.
July, 1998 - June, 2000 Meridian Automotive Systems Ionia, MI
Manager of Industrial Engineering
Developed and managed IE Department of two (2) engineers focusing on
designing and implementing process improvements, Bills of Materials and
Routings accuracy; achieved results improving inventory tracking and
standard costing, accurate future program costing proposals for four
(4) Meridian facilities and launch and maintenance of MAPICS operating
system in Meridian facilities.
May, 1997 - July, 1998 Hayes-Lemmerz International, Inc. Howell,
MI
Facilities Manager
Lead a team of 31 (four (4) salaried project engineers, three (3)
salaried maintenance supervisors and twenty-four (24) hourly union
general maintenance associates) providing support in the production of
cast aluminum wheels. Responsibilities included day-to-day operations,
capital project planning and implementation, operation reliability
improvements, TPM systems, and facility maintenance and improvements.
May, 1995 - May, 1997 Hayes-Lemmerz International, Inc. Howell,
MI
Facilities Engineering Supervisor
Lead a team of 4 ( two (2) salaried project engineers, one (1)
facilities technician and one (1) intern) responsible for the
development and implementation of capital projects, facility
improvements, maintain operation work standards and costs and provide
manufacturing process support.
August, 1994 - May, 1995 Hayes-Lemmerz International, Inc.
Howell, MI
Industrial Engineer
Responsible for development and successful implementation of work
standards for machining operations in a UAW environment. Developed and
managed implementation of acrylic clear coating capabilities project
for cast aluminum wheels. Implemented bulk nitrogen system and
delivery system reducing annual nitrogen costs by $132K.
March, 1994 - August, 1994 Ironton Iron, Inc (Division of Intermet)
Ironton, OH
Industrial Engineer
Responsible for developing and maintaining production standards.
Supervised implementation of rust preventative tumbler to replace drip
line resulting in annual material savings of $160,000.
August, 1990 - November, 1992 Frasier & Jones Co Syracuse, NY
Industrial Engineer
Responsible for developing and maintaining production standards,
process improvements, and development of capital projects.
February, 1988 - August, 1990 Grinnell Corporation Columbia, PA
Manufacturing Engineer
Responsible for developing and maintaining production standards,
process improvements, and development of capital projects. Key
responsibility in development and justification of successful
installation of $10 million foundry mold operation.
July, 1981 - February, 1988 Crouse-Hinds Company Syracuse, NY
Manufacturing Engineer
Responsible for developing and implementing process improvements.
Education 1977 - 1981 State University of New York @ Buffalo Buffalo, NY
Bachelor of Science - Industrial Engineering
Minor - Psychology
Professional American Institute of Industrial Engineers
memberships
References Available upon request
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