Manager Maintenance
Resume:
Gary S. Barnes
Conover, North Carolina 28613
**********@***.***
TPM – Total Productive Maintenance
Maintenance Manager (Hands On)
Leadership - Change Agent Throughput Improvement Leader
Maintenance Reliability & Maintainability - CMRP Engineering Technologies Upgrades
Process Mapping Equipment Health Assessment
Team Developer/Continuous Improvement Analysis Preventive/Predictive Maintenance Applications
Electrical Estimator / Design Builds Six Sigma Black Belt Certified
Trainer and Training Development QS Lead Auditor Certified
Professional Experience
GETRAG July 2008 to January 2009
Maintenance Manager
Developed the strategies for and launched TPM.
Developed and implemented Maintenance Infrastructures and Processes.
Established the process of analyzing and standardizing the PM processes and activities.
Developed and managed the Maintenance Budget, using SAP applications.
Facilitated team activities for equipment improvements consisting of Engineers and Skilled Technicians.
Initiated and implemented initiatives on Equipment Reliability.
D-Max February 2007 to July 2008
Maintenance Manager
Established and analyzed policies for maintenance activities and processes. (Arc Flash, ESWP, Lockout, etc…)
Collaborated with peers to establish best practices for MTTR & MTBF, and reduced overtime and improved the
optimization and utilization of department personnel.
Developed KPI's for Continuous Improvement for Equipment Uptime goals.
1994 – 2007
DaimlerChrysler
Divisional Total Productive Maintenance Implementation Manager, Detroit, Michigan - 1999 - 2007
Duties included Training, Development, Mentoring and Coaching of TPM processes and activities towards TPM checkpoints
as cascaded down to each plant’s support staff. Responsibilities included:
Developed and established Maintenance Infrastructures and Processes for TPM processes. Reducing MTTR by up to
30% and increasing MTBF by 40%.
Trained, coached and mentored all plant support staffs and teams.
Interacted and participated with TPM Teams at plants to identify and solve problems and then developed reliability
processes for sustainment.
Liaised with TPM Support staff and Team Members focusing on equipment wellness and auditing awareness.
Facilitated and participated in the alignment of the TPM Teams Goals to that of the Plant's Goals.
Achieved 100% launch of Total Productive Maintenance (TPM) in Components Division, Stamping Division and
Assembly Plants.
Bolstered each plant during the planning and implementation applications for Plan Development (Microsoft Project).
Coached plant TPM Teams to increase the Overall Equipment Effectiveness (OEE) from average of 35% to 70% through
80%. Continually improved the throughput capability and reliability of the equipment.
Maintenance Area Manager, Perrysburg, Ohio - 1997 - 1999
Responsible for development and utilization of Maintenance Processes that supported production and established continuous
improvement for equipment efficiencies.
Developed the documentation or QS9000 certification. (UL Certified as Auditor Assessor.)
Developed Effective Work Procedures for the CMMS. Reduced non value PM activities by 30%.
Initiated live work order system and response processes.
Established PM, Pdm and CM maintenance crews, focused on Cost Savings. (One quarter saved $250,000 avoiding a
catastrophic bearing failure on Stamping Press.) The Pdm process saved in excess of 3/4 million dollars annually.
Initiated reliability applications through root cause analysis and cause and effect analysis and reviews.
Sponsored maintenance teams that interacted with production and engineering. The cross functional teams saved
hundreds of thousands of dollars per year through continuous improve ments.
Maintenance Supervisor, Perrysburg, Ohio - 1996 - 1997
Supervised maintenance support for production and engineering. Supervised the TMS program for conducting planned
maintenance and predictive maintenance.
Interacted and supported skilled trades focusing on appropriate Preventive and Predictive maintenance activities. (MTTR
& MTBF) Improved uptime from average of 78% to 98%.
Established spare parts usage and cataloging, using excel spreadsheets.
Provided current and accurate tool stores listings in maintenance area for skilled trades.
Organized maintenance structure and response procedures.
Developed and placed an equipment library in skilled trades area.
Responsible for the planning and scheduling of installations and repairs.
Worked with engineering in the design of control applications.
Maintenance Electrician, Kokomo, Indiana - 1994 - 1996
My responsibilities included electrical controls troubleshooting and construction. Used various computer aided trouble -
shooting devices such as PLC’s, scopes and frequency meters etc
Interfaced with engineering to improve MTTR & MTBF on equipment and initiated reliability and maintainability
practices in our department. reduced downtime by 25%.
Moorehead Electric Company, Marion, IN 1992 - 1994
Regional Area Manager
Managed construction projects of eight counties; Negotiated contracts for time and material installations; Supervised
electrical estimating and provided project management; Designed electrical systems and application s for commercial and
industrial facilities.
Prepared and estimated industrial and commercial projects as well as design -build projects.
Reviewed and analyzed PLC ladder logic and controls applications.
Managed projects and developed project time lines.
Managed projects across the U.S. for Foster Forbes/American National Can installations.
Transilwrap Company Inc., Chicago, IL 1990 - 1992
Corporate Engineer
My responsibilities focused on Electrical and Industrial Engineering. I was responsible for development and installation of
equipment and machinery upgrades. Managed plant layouts and monitored costs for facilities utilities. Managed cost
reductions, both in manufacturing and facility activities.
Engineered equipment layouts and product flows.
Managed contractors, and prepared specifications and secured bids.
Initiated process for cost savings and reductions. Saved and estimated $400,000 on equipment installations.
Reviewed, monitored and audited regulatory requirements for equipment disposition and air quality.
H. J. Osterfeld Company, Dayton, OH 1986 - 1990
Government Divisions Manager 1987 - 1990
I managed the construction and maintenance contract at Wright Patterson Air force Base in Dayton, Ohio. Yearly volume
was $17 million per year, with as many as 200 projects per year. I coached and managed the engineering staff of 5 in
addition to a construction and maintenance staff of 13 direct reports with an average of 170 hourly personnel.
Electrical Project Engineer 1986-1987
Reported to Base Project Manager. Responsible for managing and estimating electrical projects. Promoted to Project
Manager and then to Government Divisions Manager.
Responsible for project costs and project timelines.
o Interacted with engineering disciplines against cost impacts.
Responsible for the design of electrical systems and coordination with air force engineering personnel.
Moss Electric Inc., Muncie, Indiana 1985 to 1986
Commercial & Industrial Electrician
Reported to President and foreman at each site location, once assigned. Electrician for Industrial and Commercial installations.
Performed industrial electrical estimating and performed construction installations and provided engineering for the Borg War ner
facility. Started designing projects for Borg Warner through Moss Electric as a subcontractor. Designed installation layouts for
vendors supplying production equipment to the plant.
Interacted with plant engineering and contractor on e lectrical installations, designs and estimates.
Oilar-Barnes Electric Inc., Richmond, Indiana 1979 to 1985
Commercial & Industrial Electrician/ Vice-President
Negotiated and administered electrical contracts and sub -contracts. Estimated and designed electrical commercial and
industrial projects. Designed electrical controls and panels for Johns Manville Corporation’s design an d research group.
Managed contracts and projects.
Estimated electrical projects. (Heavy Industrial and Commercial)
Designed projects for design builds and private concerns.
Designed electrical controls and panels.
Education M.B.A. Heidelberg College
Master of Arts Ball State University
Bachelor of Science Purdue University
Associate of Science, Industrial Engineering Purdue University
Electrical Estimating NECA
Electrical Apprenticeship
Electrician – Industrial / Commercial
ICS Scranton PA – UM
Electrical Power Engineering
Electrical Design Chicago Technical College
ADDITIONAL
INFORMATION Graduated with Distinction Bachelor of Science Purdue University
Distinguished Engineering Student in Industrial Engineering Purdue University
Distinguished Graduate from AIT in US Army
Member of the Society of Maintenance and Reliability Professionals ( SMRP) CMRP
Member of Association for Maintenance Professionals (AMP)
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