ROBERT SCHAEFER

*** **** **. **** * Wakefield, MA 01880

440-***-**** abn992@r.postjobfree.com

OBJECTIVE

Plant Manager position that will capitalize on my problem solving skills and business

experience to promote profitability and growth through teamwork, quality improvements,

Six Sigma problem solving, cost analysis, and implementing productivity improvement

teams. Extensive experience in managing compression and plastic injection molding

operations.

SUMMARY OF QUALIFICATIONS

• Operations Manager, leading performance / growth oriented operations including rubber

compression molding for automotive industries and plastics injection molding for natural gas

applications

• Managed implementation of Honeywell Operating System and Parker Lean Initiatives

• Experienced in implementation of Toyota Production System / Lean Manufacturing processes

• Implemented BPCS, PACS and EMS business systems / ISO9000:2001 QS9000 TS16949

• Proven track record of managing growth oriented companies

• Certified APICS CPIM and Six Sigma Green Belt

PROFESSIONAL EXPERIENCE

Ops-Core / Gentex 1/2012 – Present

Designer and manufacturer of Ballistic Helmets

Operations Manager,

Responsible for increasing productivity by 100% in an extremely fast growing business.

Implemented 6 Lean Manufacturing Teams and converted from batch processing to single piece flow

manufacturing. Introduced the organization to visual management by installing hour by hour boards

and developing Tier meetings to improve communications. Managed the growth in employees from

45 to over 100 associates in 8 months.

Honeywell International, Dayton, OH 6/2010 – 12/2012

Designer and manufacturer of Fire Fighting Apparel

Site Leader Honeywell First Responders Products,

Responsible for facility with 450 employees and managing 10 salaried employees. Direct P&L

responsibility for business units with annual sales of $ 100 million. As site leader responsible for

integrating all aspects of the facility including Sales, Marketing, Customer Service, Engineering and

Manufacturing. Produced custom made garments for use in the Fire Fighting markets.

Specific accomplishments included:

• Consistently meet corporate Operating Plans and profitability

• Improved OTTR from 86% to + 95%

• Implemented HOS (Honeywell Operating System) through Phase 2

• Implemented Tier 1 – 4 Meetings to promote communication.

• Successfully transitioned our Ohatchee facility into the Dayton plant on-time and on-budget

• Responsible for the coordination and implementation of our second transition of the year by

moving our Montreal facility (a cellular sewing process) into the Dayton plant.

• Developed process improvements to reduce manufacturing costs by $ 500,000 in first year

• Implement a major organizational change by adding a second shift to reduce overtime and

indirect labor costs and increase capacity.

Robert Schaefer page 2

Elster Perfection, Geneva, OH 5/2008 – 6/2010

Injection Molder / Extrusion of polyethylene, polypropylene components

Plant Operations Manager,

Responsible for managing 10 salaried employees and 80+ hourly employees. Direct P&L

responsibility for two business units with annual sales of $ 12 million. Produced injection molded

parts and extruded products to the natural gas and hot water industry. Key customers include all

Natural Gas Utilities, Rheem, Victaulic and GSW.

Specific accomplishments included:

• Within the first 9 months reduced operating losses by 50% with in the first 9 months.

• Implemented SPC tracking charts to improve product quality and reduce scrap by 8%.

• Installed a 24 / 7 work schedule and improved deliveries to 95%

• Re-organized operating staff to capitalize on strengths of organization

• Identified mold design flaws and implemented corrective actions to improve process repeatability.

• Designed single piece product flow in assembly areas and implemented new work cell teams.

• Proficient in using SAP and RJG in injection molding operations.

Parker Hannifin Corporation 4/2007 – 5/2008

Parker Integrated Engineered Seals, Chicago, II

Manufacturer of polymer products used in the automotive markets.

Business Unit Manager,

Responsible for managing a staff of 9 salaried and 160+ hourly employees. Direct P&L responsibility

for the Business Unit with sales of $ 25.5 million. providing metal / polymer seals to GM, Ford,

Chrysler and major Tier 1 suppliers.

Specific accomplishments included:

• Improved ROS from 0% to 3.5%

• Implemented lean manufacturing concepts to reduce molding labor by 30%

Parker Specialty Products Group, Milwauke, Wi 10/2004 -

04/2007

Manufacturer of polymer products used in the agricultural / automotive markets.

Business Unit Manager,

Responsible for managing a staff of 8 salaried and 50+ hourly employees. Direct P&L responsibility

for Business Unit with sales of $ 7.5 million. Key activities included developing marketing strategies

to increase sales and reduce operating costs by implementing lean manufacturing and quality

improvements.

Specific accomplishments included:

• Maintained profitable operating performance in a declining, mature product markets

• Developed current state and future state plans for Tine Cell value stream. Process includes re-

engineering the manufacturing process

• Designed a quick disconnect product to reduce customers direct labor and increase our market

share

• Certified Six Sigma Green Belt, project reduced scrap by 75% generating $ 9,000 in annual savings

Robert Schaefer page 3

Fire-Dex Inc., Medina, OH 2001-

2004

Designer and manufacturer of high quality, specialty fire-fighting apparel with an annual growth rate

above 10% and sales of $6.5 million.

Plant Manager,

Responsible for managing a staff of 5 supervisors and 62 hourly employees. Key activities included

resolving quality issues, controlling manufacturing expenses, handling human resource problems,

developing new product designs and insuring compliance to the third party certification standards.

Specific accomplishments include:

• Implemented a new team based sewing work cell, which reduced labor by 50%. This process is

easily adapted to any labor intensive, repetitive manufacturing operation.

• Managed the transition of work force from 75 employees to 62, without disrupting on-time

shipments or adding overtime expenses.

• One of the first companies in the industry to achieve ISO 9001, 2000 certification December

2001.

• Implemented and trained employees to use EMS Inventory Control Systems.

• Developed inventory planning reports to increase inventory turns from 9 per year to 13.

• Reduced lead-time from 6 weeks to 4 weeks on custom orders and from 2 weeks to 1 week on

express items. Our goal is to produce all products within 5 days or less.

• On-time delivery performance of + 98%.

• Utilized six sigma problems solving techniques to resolve design issues to insure compliance to

NFPA standards.

IER INDUSTRIES, INC., Macedonia, OH 1987 –

2001

Leading compounder of specialty synthetic elastomers and molder of precision molded seals for the

automotive, industrial and aerospace markets, with annual sales in excess of $ 26 million.

Operations Manager, 1996 – 2001

Reported to the COO with direct profit and line accountability for two (2) manufacturing facilities,

including 175 employees. Directed senior staff of five including Engineering, Purchasing,

Manufacturing (2), and Quality Assurance. Manager of a third injection molding facility purchased in

September 1999.

• Managed and staffed the organization to sustain a growth rate of 15% per year.

• Implemented and directed registration to QS-9002 / ISO 9000, November 1996. Achieved re-

registration to QS-9000 3rd Edition, February 1999.

• Coordinated Six Sigma Problem Solving Teams to implement process improvements.

• Lead Continuous Improvement Teams to reduce manufacturing variances and improve product

quality.

• Designed and coordinated the construction of a new 60,000 square foot manufacturing facility.

Transition was accomplished with no quality issues or lost productivity while maintaining a 98%

on-time delivery performance.

• Reduced and maintained inventory levels to 12 inventory turns utilizing Kanban, JIT, Lean

Manufacturing Concepts and MRP tools.

• Coordinated and implemented Value Analysis Studies and Lean Manufacturing concepts.

Robert Schaefer

IER INDUSTRIES, INC., Macedonia, OH 1987 –

2001

Plant Manager, 1987 – 1996

• Managed daily operations of two manufacturing facilities.

• Developed and installed BPCS Business Management and Control System.

• Reduced overhead multipliers through expense control and improved utilization of non-value

added activities.

• Established lean manufacturing work cells, promoting teamwork, quality improvements and

productivity.

Additional Work Experience:

EATON CORPORATION, Roxboro, NC

1976 - 1987

Manufacturing Manager,

• Responsible for all direct line manufacturing activities producing injection molded tubeless tire

vales representing 30% of the Division's annual sales.

Production Inventory Control Manager / Customer Service Manager,

• Supervised the planning of all material purchases, shop order issues, inventory levels and

warehousing functions.

EDUCATION

MBA, DUKE UNIVERSITY, FUQUA SCHOOL OF BUSINESS

B. S., Business Administration, ASHLAND UNIVERSITY

• Certified by APICS in Production Inventory Control Management

• Parker – Taking Charge of Change Seminar, Lean Boot Camp, POP, Green Belt

• Honeywell – Six Sigma Green Belt

• Honeywell – Lean Operating System Training

• Honeywell – Plant Manager Training Parker – Taking Charge of Change Seminar, Lean Boot

Camp, POP

Contact this candidate