Robert S. McCarn, PSCMC C: 713-***-****

P.O. Box 1556 Norman, OK 73070 abnaeg@r.postjobfree.com

MANUFACTURING TEAM LEADER

Start-up ? Turn-Arounds ? JIT

Aircraft Power Generation OEM

Accomplished executive with foundation of experience in manufacturing

engineering and collaborating with internal customers. Moved to supplier

management and development, combining management experience, strong

production and process skills. Builds productive partnerships for win/win

programs with a strong sense of urgency and purpose. Successful at

improving business using lean synchronous manufacturing solutions in a JIT

"Pull" production control environment. Always focused on meeting customer

requirements for absolute quality, on-time delivery, at a reasonable cost.

Communication to all levels; data collected and summarized to allow all

teams to manage and respond.

Career Highlights

Mitsubishi Caterpillar Forklift:

? Developed suppliers which lowered purchase part costs a yearly average

of $580K in a $15.5 M arena using both American and off shore

suppliers, Audit and Supplier Development in China, Canada and Mexico.

? Negotiated, Championed and Managed Robotic Welding Project $1.2M on

time and on budget.

Teledyne Continental Motors:

? Designed, negotiated and implemented JASSM Advanced Turbine

Manufacturing Cell Project with annual savings of $640K. in $14.6 M

project

? With cross-functional team, established budget, prioritize supply

resource flow and delivery, controlled inventory,

Supported MRP and Kanban replenishment system for JIT/ 2 day delivery

staging for turbine engine production

? Championed business plan and integrated mfg, quality, finance and

purchasing members into cohesive team.

? Program was done on time, to budget, with stakeholder support both

internal and external (DMAIC).

? Project matrix used to verify reduced setup 35%, cycle time 42%, space

56%, throughput 55% and purchase content 42%. First pass inspection 100%,

3.4 DPMO

? Designed and implemented Piston Cylinder Processing Cell with annual

savings of $316K.

? Managed budget, championed business plan and managed start up of

new line and first weeks of production

? Both project had FAA and Mill requirement as well as AS9000

Mellies Products:

? Consistently maintained cash flow within 93% of target.

? Took an $18M company to $21.2 first year and $24.4 second year.

Landoll Corporation:

? Quoted, developed and managed 9 new product programs: 5 military, 2 OEM

& 2 in-house.

? Orchestrated "pull" one piece flow with Kanban.

? Led tooling team to new fixture concept for $268K annual savings and 72%

space utilization reduction.

? Organized Maintenance Department which increased machine up time by 68%

cost/yr of each machine.

Contract to Boeing

? 737 Wing drill and rivet program managed tooling and machinery

installation and startup

? A6 re-wing Project, titanium-graphite flex, prep and machining of

components

? Eagle project B52 board repair and trouble location identificaion

Standard Havens:

? Turned around with full product and facility redesign. Moved $4M annual

loss to a $4.2M profit. Company sold.

Murphy Industries:

? Turned around after 6 years in bankruptcy to profit in 3 months.

Areas of Expertise

Manufacturing

Heavy Fabrication Welding, Machining & Assy PAPP, DFM, GT, BOM

flattening, MAPICs

Paint Application & Drying Systems Value Stream Analysis

Robotic & Automated Industrial Projects Team Building, 5s, Trainer, Kaizen,

Six Sigma

Lean Synchronous Production Systems, JIT "Pull" TQM, ISO 9000, AS9100,

Ford Q1, FEMA

Capital Equipment & Facilities Projects Testing, Quality and MRB Management

Supplier Management & Development

Supplier/Vendor JIT Pardoners, MRP Developed Global Supply Program

OEM / Military Project Management & Logistics Teamed w/Design Eng.

Effective Price

Trained in Import Agreements/Restrictions New Product Development &

Introduction

PSCMC Certification Risk and Cost Reduction Strategies

Robert S. McCarn, PSCMC ? Page 2

Professional Background

HITACHI COMPUTER, Norman, OK- Sr. Buyer Sheet Metal & Electronics -$ 41M

annual Apr 2009 -- Oct 2009

MITSUBISHI CATERPILLAR FORKLIFT AMERICA, Houston, TX Sept 2003 - Feb

2009

Manufacturer and distributor of material handling equipment and parts

Senior Commodity Manager, Supplier Development, Localization Project

Managed 12 North American & Asian suppliers -- $15.5M annual purchases,

assessments and continuous improvements.

. Championed with lead Design Engineer for a program that used powdered

metal process for highly machined parts that were welded in the plant.

Annual cost savings from the quotations were $278K, with ROI of seven to

nine months.

. Identified $327K in parts from Japan to move to local sourcing.

. Teamed with Engineering on several projects to review the

manufacturability of parts in the preliminary stages of design. This

often offered cost saving alternatives both in materials and in process

concepts. Result was cost savings of $740K per year.

. Directed four supplier reductions totaling $467K (two others are

pending.)

. Teamed with Production Capacity Planning Manager, to ensure the entire

supply chain is aware of performance issues

and takes appropriate actions to solve issues & increase

profitability by bridging gaps between different departments.

. Consolidated two suppliers, saving $71K annually.

. Negotiated with three global suppliers for $821K savings.

. Identified welded fabrications to change for castings with an annual

savings of $276K.

. Certified new domestic supplier for $175K parts to start with savings

of $38K.

Senior Manufacturing Engineer, Fabrication

Spearheaded continuous improvement of forklift fabrication plant. Major

core products were masts and frames. Worked with four supervisors per shift

and 168 associates.

. Increased throughput 31% by use of value stream analysis and innovative

design of mast area. Designed outer mast fixture and negotiated purchase

for $325K, saving $71K.

. Team for design of powder coating and conveyor system -championed design

of power and free lines with lowerators for putting frames and masts on

the line in constricted areas.

. Designed and purchased apply and tack style fixtures for masts,

reducing tolerance and location errors 83%.

. Designed, purchased & implemented Frame Robotic Welding Project with

$1.2M budget, and 8 robots in 4 cells with positioners. End effectors

attached 8 frame models to positioners holding critical axle spacing.

SUPERIOR INDUSTRIES INTERNATIONAL, Fayetteville, AR 2002 - 2003

Manufacturer of Tier 1 OEM alloy wheels

Manager of Production Machining

Directed 6 supervisors and 118 operators for 2 shifts/6 days. Scheduled

teams, machines & manpower for 60,000 wheels/wk. for 18 models based on

shipping schedule, with supply coming from casting schedule. Developed,

evaluated, and improved production processes. Trained production workers on

safety, quality, and productivity requirements. Interpreted specifications,

blueprints, and job orders for workers.

. Production schedule produced a favorable monthly budget variance,

saving an average of $50K. Purchases

Controlled, tracked and maintained at zero over age including cross-

docking to move parts straight to need area.

. Teamed with Quality Engineering in developing a traceability / audit

program, verifying production self-inspection and audit specifications.

. Lead in managing the vital needs for 5S housekeeping, timely

attendance and positive responsiveness.

. Established standardized procedures in the form of Visual Work

instructions in both English and Spanish for the 29 wheel styles. This

included set-up and during process to insert change of cutting tools with

strict adherence to safety requirements of full robotic cells.

. Instilled ownership with employees which resulted in increased

efficiency of 18%, $71K in six months.

. Reduced scrap three consecutive months in row, saving 9600 lb. of A356.

Robert S. McCarn, PSCMC ? Page 3

TELEDYNE CONTINENTAL MOTORS, Mobile, AL & Toledo OH 1999 - 2002

Manufacturer of turbine and piston engine for aircraft, missiles & drones

for military use

Business Unit Leader / Senior Manufacturing Engineer Manager

Second Shift Plant Leader, Toledo Plant

Designed and implemented lean synchronous single piece flow for the Advance

Turbine Manufacturing and the Continental Piston Cylinder Cells. Supervised

construction and machinery installation. Startup and operation was

accomplished with team of four manufacturing engineers. Completed cells

manned with 11 operators

. WIP was reduced from the benchmarked Harpoon Program 58% with 16-day

cycle time reduction and labor utilization improved 40%. Quality had 150%

improvement while inspecting CTV's 100% and net annual savings $860K.

. Achieved additional labor savings from reducing the cell job

classifications to one. Offered premium pay to a turbine technician,

while doing away with operators, material handlers and inspectors.

. Changed concept of inspection from manual go/no-go gauging to scanning

CMM inspection at operation. Saved tooling by $527K, increased available

tolerance by 30%, and maintained a Cpk of 1.87 with no scrap or rework.

. Increased available tolerance by 30% with an automated scanning

inspection & four-fold speed increase. Used value stream mapping,

eliminated waste/interruptions, established TAKT, reduced variable, and

created a single piece flow (double "U").

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PHOENIX CORPORATION, Ottawa, KS 1998 - 1999

Manufacturer of aerial work platforms for the sign industry

Plant Manager

Made changes to flow which reduced congestion and bottlenecks. Standardized

welding procedures and modified fixtures. Brought shop to EPA and Kansas

hazmat requirement. Developed PPE program for painting and welding.

Directed seven supervisors and 58 hourly in a non-union shop.

MELLIES PRODUCTS, INC., Morganville, KS 1996 - 1998

Metal fabricator

Operations Manager

Handled cash flow, analysis of capital equipment, lease and loan expenses,

insurance, human resource program, logistics, MRP & network. Managed 34

hourly shop and four office staff. Maintained annual cash flow of $2.25M.

. Increased sales by 18% growth first year, followed by 30% second year.

. Accelerated development of new products. Implemented flow, tooling, and

fixtures to work correctly.

. Implemented air assisted electrostatic painting to increase quality and

efficiency savings by four hours per day.

LANDOLL CORPORATION, Marysville, KS 1989 - 1996

Manufacturer of trailers, farm tillage, forklifts, aircraft ground support,

military & OEM equipment

Assistant Plant Manager

Managed bids, new processes, first production, and project audits.

Instituted yearly machine orders, tracking labor and materials, and

analyzed machine values. Implemented MRO parts area, with quantities and

location in database. Established metrics for auditing routings, BOM,

critical material path and Kanban sequences. Directed eight office and 40

direct staff in Process Engineering, Maintenance & Tooling departments.

. Led Tooling department design of new fixture system which saved 72%

storage space and reduced set-up time by 8.5%.

. Reduced manufacturing cycle time three days by developing "Pull Kanban"

fabrication / welding cell. Involved continuous flow, high tolerance

sheet aluminum, and sheet steel skid bases with pokayokes, increasing

productivity by 34%, with savings of $365K.

. Initiated CAM program, automated nesting and DNC to cutting tables and

punch centers on the plant floor.

. For military contracts designed and implemented: a seven-stage wet top

coat and prep system that could exceed 2000 hours salt spray levels; AWS

weld map, including specifications and training program for welding of

steel sheet metal, aluminum and stainless, and DOD-approved standard

database program.

. Implemented maintenance and skill training which resulted in a 68%

improvement in machine up-time, including data base for spare parts and

staff skills.

. Working in cross-functional environment (Engineering, Operations,

Quality, Sales and Customer) designed and planned supply chain program

with prioritized demand requirements in a pull system, with key planned

inventory points in a FIFO minimum age program (7 days) as part a the

production plan to both internal & external customers.

Robert S. McCarn, PSCMC ? Page 4

Additional Experience

Standard Havens: Successfully turned around business in two years which

resulted in the sale of the company.

Collins Division: Reduced unit cost $11K. Moved the tires service truck

company to #2 rank in the nation.

Murphy Industries: Turned around company to profit in eight months, after

company had been in bankruptcy.

Millwright Trade Craft: General Foreman. Industrial, Power Generation,

Automotive and Agricultural projects.

Education and Professional Training

University of Houston: Purchasing / Supply Chain Management Certificate

Lockheed, Teledyne and Caterpillar: Six Sigma Green Belt

Additional coursework: Military Procurement; Fars; Dfars; Ethics;

Restricted/banded Countries; TACOM Welding; Project Management; Value

Engineering; GTD; CIM, CAM, CAD; MS Office & Project

University of Houston - Supply Chain Management

California Institute of the Arts ~ Masters, Design ? Kansas

City Art Institute ~ Bachelor of Arts, Design

Ford Foundation Study Recipient ? Danforth Scholar Nominee

Affiliations

Society of Manufacturing Engineers; American Welding Society, American

Foundry Society, APICS, ISM, NAPM

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