Ron Bakos

** ********* *****, ***********, ** ***05 Home:309-***-**** Mobile: 309-***-**** E-mail:

abnwfz@r.postjobfree.com

Proven, results oriented manufacturing manager with over twenty years of experience including nine as

Plant Manager for both individual and multiple locations. Expertise in numerous production processes

including manual and automated assembly, metal stamping, injection and insert injection molding of

plastics, circuit board population, glass melting, reinforced composites, welding, roll forming, powder and

liquid painting. Skilled in the utilization of Lean Manufacturing, Six Sigma and Theory of Constraints

methodologies in both union and non-union environments. Core competencies include a strong technical

ability, excellent communication skills, the ability to develop a motivated team environment then use that

team to solve complex problems. Documented career of improving quality, safety and productivity while

reducing manufacturing costs.

Professional Experience

Plant Manager

United Fixtures Interlake, Pontiac, IL

October 2007 – March 2009

Held complete management responsibility of the largest steel pallet rack manufacturing site in the U.S.

Full P&L responsibility for 350 employee site, generating $85M in annual revenue.

Accomplishments include:

Increased total plant output by 22%, through uptime improvement of the process constraint.

Reduced scrap by 18%, a $235,000 savings by improving equipment maintenance and operator

involvement.

Reduced inventories by $3.1M, a 35% decrease through better information accuracy and supplier

communications.

Reduced labor grievances 66% by consistent application of the labor contract.

Implemented comprehensive continuous improvement program which contributed to an earnings

improvement of 17% over previous year.

Group Plant Manager

Superior Fibers (formerly Hollinee Glass Fibers), Vanceburg, KY and Shawnee, OH

February 2003 – October 2007

Held management responsibility for two glass fiber composites reinforcement manufacturing plants,

totaling 300 employees. Full P&L responsibility for both locations, with annual combined sales of $25M.

Responsibilities included product manufacture and delivery, quality, human resources, employee safety,

building and equipment maintenance and environmental compliance.

Accomplishments include:

Reshaped manufacturing model by coordinating transition of primary manufacturing site to lower cost

non-union facility.

Integrated two plant support organizations, reducing headcount by 25%, and generating a $330K annual

savings.

Improved net yield by 3.8%, representing a $441,000 savings which includes a year over year finish

process scrap reduction of $165,000. This was achieved through process variation reduction activities.

Internalized finished goods storage, closing leased warehouse space, a $252,000 annual savings by

reducing on hand inventory and a plant layout reorganization.

Integrated manufacture of 300 products for the European market, facilitating a plant consolidation.

Negotiated 3 year labor agreement netting savings of $1.4M, managing through a seven week work

stoppage without customer supply interruption.

Implemented a control plan based process monitoring and product testing program, realizing a 28%

reduction in returned product, a 46% reduction in customer complaints and an $81,000 savings.

Reduced lost time injuries by 43% through education, employee involvement and implementation of a

comprehensive 5S program.

Plant Manager

Lear Corporation, Zanesville, OH

April 2000 – February 2003

Held general management responsibility for 700 employee, $70M, Tier 1 automotive electronics parts

manufacturing facility. Responsibilities included manufacturing cost control, product quality, delivery,

engineering, plant human resources, facility and equipment maintenance.

Accomplishments include:

Implemented Six Sigma program resulting in $2 M annual savings.

Negotiated 5.75 year labor agreement, contractually establishing self directed work teams.

Initiated and managed transition from electrical to electronic products, outsourcing metal forming and

insourcing plastic injection molding operations.

Managed a $7M facility upgrade to facilitate electronics manufacturing processes.

Reduced salary headcount 25% with no degradation to plant performance, saving $525,000 annually.

Reduced on hand inventories by $2.5M through implementation of a Kanban pull system for component

parts.

Manufacturing Engineering Manager

Kenworth Truck Company, Chillicothe, OH.

March 1999 – April 2000

Managed department of engineers who were responsible for the conception, economic analysis, acquisition,

installation and maintenance of capital manufacturing equipment used to assemble class 8 trucks.

Responsibilities included production efficiency improvement, product quality, ergonomics and employee

safety.

United Technologies Automotive, Zanesville, OH

Production Manager

September 1997 - March 1999

General management of a production operation employing 400+ associates through 5 direct reports. Duties

included cost containment through meeting production efficiency, cost per hour, premium freight, and

spending variance goals. Additional responsibilities included product quality, inventory control, on time

delivery and equipment maintenance. Named interim Plant Manager during extended illness of Plant

Manager, receiving letter of recognition and stock award from Vice President of Operations.

Quality Manager

April 1991 – September 1997

Areas of responsibility included supplier quality, product testing lab, and quality engineering for three

production organizations. Responsible for new program planning through Advanced Quality Planning

processes, and ISO9000 registration.

Quality Engineer

Dearborn, MI and St. Matthews, SC

May 1986 - April 1991

Duties included control plan adherence, product failure analysis, statistical process control, and advanced

quality planning for new product lines. Functioned as customer liaison to Ford and Chrysler assembly

plants.

Education

Master of Business Administration, University of Findlay, December 1997

Bachelor of Science, Automotive Technology, Western Michigan University, December 1985

Formal Training

Six Sigma Greenbelt Kaizen Continuous Improvement

Lean Manufacturing Kepner Tregoe Problem Solving Methods

Statistical Process Control Project Management

Capital Equipment Purchase Negotiations Total Predictive Maintenance

Mistake Proofing Visual Workplace

Technical Skills

MS Office: Word, Powerpoint, Excel and Outlook

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