Quality Management

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ZACHARY R. FETZER

**** ****** **. / *******, ** 49348 / H: 269-***-**** / C: 248-***-**** / abnma2@r.postjobfree.com

PRODUCTION MANAGEMENT

Production Supervisor / Plant Superintendent / Kaizen leader / Continuous Improvement

Highly ambitious and dynamic thinker, who is driven to succeed. That possesses a very willing personality who is

motivated to continue learning new skills and knowledge. Areas of expertise include high interpersonal

communication skills, motivation, leadership, team training, continuous improvements, equipment layouts, and

process flow. With proven skills in kaizen, decision making, team management, and problem solving.

PROFESSIONAL EXPERIENCE

THE BROWN COMPANY OF IONIA, Ionia, MI 2004 to Present

Production Supervisor (2007 to Present)

Manage the production operations for a first shift automotive robotic welding, and assembly department. The

department has forty to fifty employees. We manufacture Instrument Panels, Consoles, Seat backs, Seat

Frames, Airbag Doors, and other inner mechanisms. The department maintains a clean, safe, quality conscious,

highly efficient work force. We demand zero quality defects, and corrective actions are assigned for all

determined issues. The department maintains an average OEE of 80% or better. Weekly audit the department

for safety, quality, organization, and production. Responsible for assigning the work force properly, leading to

our planned production goals being completed efficiently and effectively. I strive to sustain a 5’s system in the

department and continually improve processes through the PDCA process. Using my Kaizen background to

initiate the improvements, implementing enhanced part flow and presentation.

First year accomplishments:

• Successfully launched two new production lines with minimal quality defects.

o Instrument panel for the 2009 Dodge Ram, consisting of two robotic mig welding cells, one robotic

resistance weld cell, two tube swag and pierce machines, and two resistance sub welding cells. (17

quoted operators).

o Seat back frame for the 2009 Lincoln MKS, consisting of three resistance welding cells, and one

robotic welding Ferris wheel. (5 quoted operators).

• Through continuous improvement activities, and cycle time studies, reduced labor on the new launches by

8 employees. ($280, 000 average savings).

• Relocated and redesigned a console line layout that reduced labor from four operators, down to two

operators ($75,000 average savings).

• Averaged 80% and above OEE.

• Closed outstanding quality alerts previous to taking over, utilizing the PDCA system, putting corrective

actions in place to prevent future failures.

o Finished 2008 with zero quality defects.

Kaizen Leader

I managed a small Kaizen team with three members; two fabricators, and one machine tech. I designed and

constructed new and improved ideas to enhance process flow, lowered inventory levels, increased uptime, and

eliminated operator walk steps, for all work cells in the factory. I provided new layout proposals for defined

work cells requiring improved flow and ergonomics. I develop new and improved SWI for all the improved

work cells. I eliminated unnecessary operations and combined operations to eliminate excess manpower.

Accomplishments:

• The first task completed, including two new cell layouts and combining of processes, to reach a total cost

savings of $175,000, including a reduction in labor of five employees.

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ZACHARY R. FETZER

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Continuous Improvement Coordinator

I coordinated continuous improvement activities throughout the plant facility. I worked with a continuous

improvement team; we were responsible for developing an action plan to improve selected production cells. We

continually improved processes, changed cell layouts to achieve optimum part flow through the cell, lowered

inventory levels, reduced rework, improved quality, and reduced labor when possible. We used time studies to

balance the operators work load throughout the cell, giving each operator equal work levels.

SKILLS

• Lean Manufacturing

• Kaizen

• 5’S

• Hand mig welding

• Robotic training

• Fluent in Word, Excel, PowerPoint, and Outlook programs

• Fluent in AS 400/MAPICS operational data system

• Dynamic thinker

• Imaginative

• Creative mind

• Strong interpersonal communication skills

EDUCATION

Milford High School, Milford MI

• 1999-2004

• Graduated, received Diploma: General Studies

Kellogg Community College

• 2005-Present

• A.S. Business management Scheduled for completion, summer 2009

Bachelors of Science

• B.S. Lean Manufacturing/Operation Management Scheduled for completion, 2011

Lean Boot Camp

• Successfully completed Lean Manufacturing course

Presented by: Richard Fleming

Leadership courses 1 and 2

• Successfully completed both courses

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ZACHARY R. FETZER

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REFERENCES

References Available Upon Request

Contact this candidate