Manager Engineer
Resume:
MAYNARD LOY
**** *****’s Point Drive
Hanover, IN 47243
*******.***@*****.***
SUMMARY
Broad based manufacturing executive with unique combination of operational management, process re-
engineering and lean manufacturing expertise. Innovative problem solver with passion for manufacturing
excellence to optimize throughput and machine availability while cutting waste. Positive, participative
management style with primary focus on employee safety, product quality, while accomplishing goals and
ensuring profitability.
PROFESSIONAL QUALIFICATIONS
Lean Manufacturing Visual Factory QS 9000/ISO
14000/TS 16949
Continuous Improvement Waste Reduction PM /PdM
Maintenance
Building High Performance Teams Theory of Constraints TPM
CENTURY TUBE, Madison, IN 2007 – 2008
Automotive Tube Manufacturer. Division of Allied Tube, Tyco International.
Operations Manager
Directed all Production Operations, Maintenance, Engineering, and Shipping.
Reorganized tube mill changeover techniques and practices. Reduced mill set up time over 50%.
Coached and developed mill personnel to perform multi-function roles during changeovers and production
runs, leading to 15% improvement in production throughput.
Organized restructuring of Preventive Maintenance program, resulting in a 50% improvement in planned
vs. unplanned maintenance hours.
ESSELTE, Kankakee, IL 2005 – 2007
World leader in manufacturing Brand Name Office Products, including Pendaflex and Oxford.
Focused Factory Manager – Lean Manager
P&L and Lean Operations responsibility for 4 Focused Factories. Reporting Manager for Production
Supervisors, Production Planners, Value Stream Maintenance personnel, and approximately 100 production
associates.
Provided management direction to turn around failing Value Stream. Implemented improvements
resulting in 25% increase in production throughput and moved production fill rate from 40% to 98+% in 4
months.
Implemented TPM procedures resulting in 15% average performance improvement to standard work for
all equipment.
Led Kaizen team to develop manufacturing cell that reduced WIP from 30,000 pieces to 2,800 pieces;
reduced floor space by 60%; reduce in-house lead time from 36 hours to 8 hours, and reduce parts travel
distance from 2300 ft to 760 ft.
Developed in-house techniques in conjunction with suppliers to ensure stable humidity control for paper
stock, accomplishing 30% decrease in paper-related production stoppages.
HUCK FASTENERS, Park Forest, IL 2002 – 2004
QS 9000 and ISO 14000 certified, Tier One manufacturer of Cold Headed, Externally Threaded Automotive
Fasteners, employing 400 workers with sales of $60 million per year. Division of Alcoa, Inc.
MAYNARD LOY PAGE TWO
HUCK FASTENERS (Continued)
Operations Manager
P&L and management of all production operations. Directed work and supervised personnel for Production
Supervisors, Production Planners, Tool Room, Quality Systems. Promoted Lean Manufacturing Principles.
Implemented “Back to Basics” quality management leading to reduction in customer complaints by 60% from
2002 to 2003.
Led safety awareness initiative to reduce number of OSHA recordable injuries by 80% in one year.
Reduced set-up time by 50% and increased cell throughput by 30% by regrouping components into
families for four machine cell, with each family running through a specific machine; developing quick-
change set-up procedures using gage blocks and standardized tooling; and writing work standards
followed by all set-up personnel.
Developed and improved Lean Initiatives ranging from manufacturing process improvements to
scheduling work flow, resulted in significant improvements in focus areas.
BORG WARNER, ATS, Frankfort, IL 1970 – 2001
QS 9000 and ISO 14000 certified, Tier One manufacturer of automotive transmission components for Ford,
GM and Chrysler, employing 500 workers with annual sales of $70 million. Processes include metal
stamping, welding, brazing, heat-treating, assembly, paper blanking. Rubber milling and molding. Injection
Molding of Rubber, Phenolic, and Plastic components. 1998 winner – Industry Week Magazine’s America’s
Best Plant.
Technical Services Manager 2000 – 2001
Technical Services department manager supervising 34 maintenance technicians, 33 Tool and Die makers, and
5 salaried supervisors and engineering staff.
Turned reactive maintenance department into motivated, proactive maintenance group focused on
production throughput through increased equipment uptime.
Introduced Reliability Engineering and Predictive Maintenance activities.
Developed cross-functional teams resulting in optimal efficiency for equipment; implemented Total
Productive Maintenance systems resulting in sustained 25% improvement in machine uptime.
Provided oversight for integrating Technical Services Department with established Lean production
program.
Rigid Band Product Line Manager 1998 – 2000
Member of Operating Staff with P&L responsibility for $12 million per year manufacturing line employing 70
production workers, 3 salaried supervisors, 2 manufacturing engineers and one quality engineer.
Developed Lean Training /Kaizen Blitz program for the Frankfort and Bellwood plants collaborating with
4-person team.
Redirected departmental focus to machine set up time reduction and departmental layout resulting in 23%
improvement in production throughput.
Reduced departmental scrap from 12% to 2.5% through daily reviews and follow-up training for all
operations.
Reduced perishable tooling costs for department by approximately 20%.
Lead Supervisor / Engineer 1997 – 1998
Production planner for a 150-employee department. Led team of 3 Engineers, 2 off-shift supervisors, and 7
Team Leaders.
Reorganized Kanbans and renewed focus on Theory of Constraints resulting in 33% improvement in day-
shift production throughput on constraint equipment.
Increased total departmental throughput by 12%.
Production Engineer/Production Supervisor 1996 – 1997
Supervised 10-person, multi-shift Paper Blanking department and provided direct engineering support.
Responsible for new equipment development and implementation of Quick Die Change procedures.
MAYNARD LOY PAGE THREE
BORG WARNER, ATS (Continued)
Production Supervisor 1996
First line supervisor for 3rd shift operation of 50-person manufacturing department.
Manufacturing Specialist (Manufacturing and Production Engineering 1995
Implemented new product launches in collaboration with Product Engineering.
Developed new processes and improved existing processes for Single Wrap product line.
Associate Manufacturing Engineer 1994
Co-project manager of product line transfer and start up between two plant operations.
Associate Facilities Engineer / Heat Treat Engineer 1993 – 1994
Plant facilities project engineer and Manufacturing Engineer for braze/heat treat operations.
Automation Specialist (Engineering/Maintenance Departments) 1983 – 1993
Provided electrical design and PLC programming and Robotics installations.
EDUCATION
MBA candidate, Olivet Nazarene University, Bourbonnais, IL
BS, Industrial Technology, Southern Illinois University, Carbondale, IL, Magna Cum Laude
TRAINING AND DEVELOPMENT
Constraint Management
8-D problem Solving
Poke-Yoke Training
Enlightened Leadership: Making Managers into Leaders
BorgWarner Leadership Effectiveness Workshop
Contact this candidate