Manager Engineer

David K. Sayers: Experienced Operations Manager and Lean Manufacturing

Implementer with the vision to improve profits, reduce lead-times, improve

quality and satisfy the customer by motivating and empowering employees

through team building, problem solving and continuous improvement.

Summary

. Eleven plus years as a hands-on Operations/Plant Manager Implementing

Lean Manufacturing and managing continuous improvement.

. Implemented Lean Manufacturing from scratch at 3 locations for union

and non-union companies.

. Improved EBITDA from 7.5% to 19% within 18 months.

. Reduced Lead-times by 50%, reduced scrap by $300K, and improved on-

time delivery from 50% to 90%.

. Empowered employees to develop team leaders specializing in 5-S, Total

Productive Maintenance, set up reduction, and Value Stream Mapping.

. Led capital improvement projects to improve productivity, throughput,

and reduce cost within a two year or less payback.

. Twelve plus years as an Industrial Engineer/Supervisor conducting time

studies, developing standards, writing routings, designing fixtures

and monitoring productivity improvement projects.

. A successful motivator, driven, people oriented, and an experienced

problem solver.

. Lean Manufacturing background is rooted in DBS and TPS while

motivation techniques are modeled from The Seven Habits of Highly

Effective People by Stephen Covey.

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CORE COMPETENCIES

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Lean / Six Sigma / Quality / Safety / Team Building / Strategic Planning /

Cellular Mfg / VSM / Visual Management / Global Supply Chain / Change

Management / Project Management / Pull Systems Continuous Improvement /

One Piece Flow / TPM / SMED

Career History

Operations Manager - Altra Industrial Motion, Global Supplier of Power

Transmission 2005 - 2009

and Motion Control Products.

. Managed Nuttall Gear, Niagara Falls, NY from July, 2005 to November,

2009.

. Nuttall Gear lost $1.O mm in 2004 and was losing $300K by July 2005

. Nuttall Gear made a profit of $600K by year-end 2005.

. Improved EBITDA from 7.5% to 19% within eighteen months.

. Reduced Lead-times by 50%, reduced scrap by $300K, and improved on-

time delivery from 50% to 90%.

. Implemented Lean Manufacturing from scratch, converted single

processes to cells within the product value stream .

. Empowered employees to develop team leaders specializing in 5-S, Total

Productive Maintenance, set up reduction, and Value Stream Mapping.

. Implemented Lean Manufacturing from scratch at Ameridrives Power

Transmission in Green Bay, WI. Converted single processes to cells

within the product value stream.

Plant Manager - Renold Inc., Manufacturer of Custom Gear Spindles and Gear

Couplings. 1998 - 2005

. Managed Renold Inc., Westfield, NY from September, 1998 to July, 2005.

. Changed the culture from a disruptive union environment in 1998 to an

empowered, productive workforce by December of 1999.

. Improved Gross Margins from 25% to 38% within twenty four months.

. Reduced Lead-times by 50%, reduced scrap by $360K, and improved on-

time delivery from 60% to 90%.

. Implemented Lean Manufacturing from scratch modeling TPS beginning in

January, 2000.

. Managed continuous improvement to improve sales from $13 mm to $18 mm

by April, 2005.

Industrial Engineer - Ameridrives International, Erie, PA (Formerly Zurn

Mechanical Drives) 1986 - 1998

Manufacturer of Mechanical

Transmission Products

. Industrial Engineer/Supervisor conducting time studies, developing

standards, writing routings, creating fixtures, and monitoring

productivity improvement projects.

. Trained in Lean Manufacturing through DBS and TPS beginning June,

1993.

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EDUCATION

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Business Administration, Mercyhurst College, Erie, PA,

Working to complete BA with a graduation date of June, 2011

Associates Degree, Engineering, Triangle Institute of Technology, Erie,

PA

880 Bonnie Brae H:814-***-**** *********@**********.***

Erie PA 16511 C:(814)

823-9150

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