Project Manager Plant
Resume:
DAVID G. HEARN
***** *. **** **. *****; Owasso, OK 74055
abnnll@r.postjobfree.com
SUMMARY
Seasoned professional with extensive experience in manufacturing, engineering,
and managerial roles. Strong leader with the experience and ability to manage
large groups of people from multiple disciplines. Student, instructor, and
practitioner of lean manufacturing techniques focused on increasing value and
decreasing waste in all aspects of the business.
EMPLOYMENT HISTORY
UMICORE AUTOCAT USA (formerly Delphi Corp.), Catoosa, OK 1979-2009
Belgium-based materials technology group that manufactures automotive
exhaust catalysts.
ACCOMPLISHMENTS
Management
• Managed a high volume manufacturing organization with an annual
operating budget of $15 million (excluding materials) and over 300 hourly
and professional personnel on a 24-hour/7-day schedule. Responsibilities
included safety performance, scheduling, throughput, machine efficiency,
scrap, and all matters related to human resources.
• Managed a group of five engineers and had global responsibility for
process development of new products. Supported sites in Oklahoma,
France, South Africa, Mexico, China, and Australia.
• Managed a group of six engineers responsible for continuous
improvement activities and facilities enhancements at the Catoosa plant.
• Supervised 25 hourly personnel on a 24-hour/7-day schedule in the Pilot
Plant area. Responsible for the manufacture of catalyst samples for
internal testing and shipment to customers and potential customers.
Engineering
• Successfully identified and reduced several sources of process variation,
resulting in savings of several million dollars in precious metals and other
materials.
• Served as Project Manager for a team that reduced the plant’s scrap rate
by over 50%.
• Responsible for resolving routine manufacturing issues on a 24-hour/7-
day basis.
• Participated in process development, machine design, installation, and
startup activities for a new catalyst manufacturing plant in France.
• Created bills of material for all commercial products to support the
introduction of an enterprise-wide business information system.
DAVID G. HEARN
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ACCOMPLISHMENTS (continued)
Lean Manufacturing
• Served as a principal member of a team that implemented the Delphi
Manufacturing System (DMS), a lean manufacturing structure modeled
after the Toyota Production System.
• Functioned as champion of Operational Availability, one of the six
elements of DMS.
• Developed an Operational Availability training plan and personally trained
all plant personnel.
• Served as the resident expert in the areas of machine efficiency,
preventive maintenance, and quick changeover.
• Initiated and presided over several Kaizen events aimed at maximizing
utilization of personnel, reducing material movement, and eliminating
unnecessary equipment.
• Led a team that used SMED and Value Stream Mapping techniques to
reduce changeover time in one area of the plant from six hours to 30
minutes.
Special Projects
• Performed a comprehensive technical and financial analysis related to the
potential movement of non-core business to a sister plant in Mexico.
• Worked with appropriate groups in both plants to facilitate the movement
of these products, resulting in a financial benefit to both plants.
EDUCATION
Bachelor of Science, Mechanical Engineering (Cum Laude), Tulsa University,
Tulsa, OK, 1989
CERTIFICATIONS
Shainin Problem Solving Methodology
Red X Journeyman
Green Y Journeyman
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