BRUCE D. SCHMALFELDT, MBA

**** ********* **** (Indianapolis, Indiana 46227

317-***-**** ( abne3e@r.postjobfree.com

PLANT OPERATIONS AND MANUFACTURING MANAGEMENT

Results-driven General Manager and Six Sigma Green Belt with a proven track

record of 15+ years of experience driving the advanced performance, growth

and profitability of diverse manufacturing organizations. Leverage Six

Sigma, Lean Manufacturing and Kaizen best practices to align all aspects of

manufacturing plant operations with corporate production goals and

objectives. Lead continuous process and capital improvement projects that

optimize production, quality and capacity while generating significant

energy and labor cost savings. Build and spearhead top-performing

engineering teams, providing the guidance and support needed to meet and

exceed both client and business expectations. Areas of expertise include:

Manufacturing Operations & Plant Management ( Project Management ( Process

& Capital Improvements

( Lean Manufacturing ( Six Sigma ( Kaizen ( Cost Reduction ( Electrical

Engineering ( Mechanical Engineering ( Quality Assurance ( Problem

Resolution( Consensus Building ( Labor, Client & Vendor Relations ( Team

Building, Training & Leadership

PROFESSIONAL EXPERIENCE

ADVANCED CAST PRODUCTS, Inc. Meadville, Pennsylvania ( 2008-October 2009

Ductile iron foundry and CNC machine shop producing castings for heavy

truck, construction, railroad and mining industries.

Vice President/General Manager (2008 - October 2009)

Responsible for plant operations of 170 employee multi-site facility with

full profit and loss responsibility (250,000 sq-ft ductile iron foundry

with approximately 100 employees, 15,000 sq-ft CNC machine shop with

approximately 40 employees and approximately 30 salaried employees between

the two sites). Responsible for ensuring Key Performance Indices (KPI) of

EBITDA, Cash Flow, Sales Dollars per Full Time Equivalent Employee, On-time

Delivery and Lost Time Accidents meet or exceed corporate goals. Developed

and delivered weekly and monthly executive presentations to President, COO

and CFO, to review KPI's. Generated and implemented corrective actions to

bring metrics back in line with goals. Managed all capital projects of

more than $100K.

Financial / Operational Highlights:

. Rolled out and implemented Lean principles to realize $600,000 in just in

time inventory reductions.

. Provided project management to facilitate installation and qualification

of $5 million molding line 45 days sooner than scheduled and $1.5 million

under budget.

. Identified, justified and managed movement of capital from sister plant

to facilitate site and corporate KPI's goals. Company interface with

affected customers during bank build, movement and qualification of the

equipment and products.

. Rolled out and implemented 5S to realize approximately $350,000 of

savings and cost avoidance in 3 month period.

. Facilitated transition from QS9000 to TS16949 Quality System.

BRUCE D. SCHMALFELDT, MBA( Page 2 ( abne3e@r.postjobfree.com

NAVISTAR, INC. / INTERNATIONAL TRUCK & ENGINE, Indianapolis, Indiana ( 1999-

2008

The Leading manufacturer of medium and heavy-duty trucks, severe service

vehicles and diesel engines.

Manufacturing Resource Leader

Responsible for the machining and subassembly of cylinder heads and

crankcases for 6.0L and 6.4L Turbo Diesel Engines, with profit and loss

responsibility. Led all manufacturing engineering activities, coordinated

and managed new model year retooling, equipment changeovers and PPAP

approvals. Allocated and directed engineering resources to expedite the

resolution of maintenance issues, bottleneck operations and to facilitate

continuous improvement activities. Managed all capital projects less than

$100K. Spearheaded production team meetings to review manufacturing

output, quality, labor relations and to generate and implement any

corrective actions necessary. Responsible for ensuring Key Performance

Indices (KPI) for Internal Customer Quality, External Customer Quality,

Production, Engineering and Maintenance are met or exceeded. Developed and

delivered weekly and monthly presentations to company executives to review

KPI's. Generated and implemented corrective actions to bring metrics back

in line with goals

Financial / Operational Highlights:

. Managed and completed 2 product line changeovers, and obtained customer

approvals in less than 1 month.

. Reduced scrap on cylinder head and crankcase production by 23% and 13%

respectively. Utilized Kaizen events to identify scrap causals and

improvements on affected operations.

. Generated a total of approximately $228K in labor cost savings after

improving equipment uptime. Utilized Kaizen events to generate need for

additional training for production and maintenance personnel and

implemented new PM procedures to facilitate the improved equipment

uptimes.

. Achieved annual savings of $548K after decreasing the overall Cost per

Unit (CPU) for cylinder heads from $34.93 to $30.16. Reduction in CPU

achieved by reducing scrap and increasing equipment uptimes.

. Achieved annual savings of $451K after decreasing the overall Cost per

Unit (CPU) for crankcases from $120.41 to $116.48. Reduction in CPU

achieved by reducing scrap and increasing equipment uptimes.

. Managed installation of robotic automation, on crankcase line, at

strategic locations to reduce the overall cycle time of the machining

lines. Resulted in savings of approximately $331K

. Avoided approximately $60K in yearly labor costs after introducing Single

Minute Exchange of Dies (SMED) and reducing the changeover time for

machine service parts from 5 days to 1 day.

. Certified TS16949 Lead Auditor

Manufacturing Technology Development Engineer

Directed all manufacturing engineering activities related to cylinder head

subassembly and short block assembly lines for 6.0L and 6.4L Turbo Diesel

Engines. Responsible for identifying and implementing new technologies to

aid in the assembly of cylinder heads and crankcases. The overall goal was

to introduce lean and six sigma principles into the production processes.

Reallocated engineering resources to facilitate the resolution of

maintenance issues and bottleneck operations. Interfaced with customer on

quality issues, containment actions and to present action plans to prevent

recurrence. Presented monthly Key Performance Indices to senior management

teams. Plant Project Manager on all capital projects in the assembly area.

Financial / Operational Highlights:

. Achieved annual savings of $600K in labor costs after instituting robotic

automation for bolt installation and leak testing.

. Maximized First Time Yield (FTY) in short block assembly lines from 75%

to 98% and in cylinder head subassembly lines from 88% to 95% after

leading Kaizen continuous improvement projects. Introduced enhanced error

proofing and poke-a-yoke devices in the assembly processes. Introduced

and refined head bolt rundown yield strategy resulting in better process

control and reduction of rejects to 1%.

. Achieved annual savings of $186K annually and minimized engine teardowns

from 590 to 124 per year after implementing Kaizen best practices to

detect leak failures at Short Block Leak Test.

. Utilized six sigma methodology (DMAIC) to identify areas or processes

needing improvement.

BRUCE D. SCHMALFELDT, MBA( Page 3 ( abne3e@r.postjobfree.com

Senior Manufacturing Engineer - Controls Engineering and Facilities

Provided project management and electrical engineering support for

machining and assembly of 7.3L, 6.0L and 6.4L Turbo Diesel Engines.

Designed and implemented electrical control changes to facilitate

continuous improvement items and to resolve maintenance issues. Project

management of all facility modifications, equipment installations and

maintenance projects for the Engine Plant. Documented work instructions

and equipment preventative maintenance activities. Collaborated with

skilled tradesmen to maintain and ensure the full operability of facility

equipment. Monitored plant electrical usage and recommended cost and energy

saving initiatives.

Financial / Operational Highlights:

. Project Manager for installation of primary switching power factor

correction capacitor banks. Achieved annual savings of $1.3M in annual

power savings

. Achieved annual savings $350K after collaborating with insurance company

to justify the reduction of high voltage maintenance activities from

yearly to every other year.

. Participated in installation, startup and commissioning of $100 million

dollar expansion to assembly plant.

. Programmed PC based controls using PCWorx and Krause template.

. Programmed ABB robots in material handling and deburr applications

. Experience with AB PLC-5, SLC-500, RSLogix 5, RSLogix 5000, RSView

FORD MOTOR COMPANY/VISTEON, Indianapolis, Indiana 1996-1999

Responsible all manufacturing engineering activities related to assembly

and test of power steering pumps. Participated in the development of

PFMEA's, DFMEA's, Control Plans, and PPAP's for new model introductions.

Received lean manufacturing training at the Ford Fairlane Training Center

and rolled out the Ford Production System to the Indianapolis Steering

Systems Component Plant. Directed maintenance resources to facilitate the

resolution of maintenance issues and bottleneck operations. Interfaced

with customer on quality issues, containment actions and to present action

plans to prevent recurrence (8D's). Presented monthly Key Performance

Indices to senior management teams. Project Manager on all capital

projects in the assembly and test area.

. Project manager for installation and start-up of two power steering pump

assembly lines and 15 test cells. Project cost was approximately $10M.

. New model launch liaison between Indianapolis Plant and Jaguar assembly

plant in Birmingham, UK. Spent 6 weeks in Birmingham, UK to facilitate

the launch of all Indianapolis components (Column, Pump, and Rack and

Pinion Gear).

. Facilitated the implementation of the Ford Production System and work

groups by training all manufacturing personnel and management teams on

Lean Manufacturing principles and methodologies.(Train the trainers,

visual factory, kanban etc)

. Certified QS9000 Lead Auditor

EDUCATION

Master of Business Administration

Indiana Wesleyan University, Indianapolis, Indiana

Bachelor of Science in Electrical Engineering

Purdue University, Indianapolis, Indiana

CERTIFICATION

Six Sigma Green Belt

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