Management Quality

John Lilly

Email: *********@********.***

Address: **** ****** ******* **

City: Indianapolis

State: IN

Zip: 46229

Country: USA

Phone: 317-***-****

Skill Level: Management

Salary Range: 80

Willing to Relocate

Primary Skills/Experience:

See Resume

Educational Background:

See Resume

Job History / Details:

John A. Lilly

2133 Orange Blossom Court Indianapolis, Indiana 46229

317-***-**** / 317-***-**** / *********@********.***

Manufacturing Management

Strategic Planning / Process Improvements / Staff Development

Relationship Management / Coaching and Mentoring

Results-producing, energetic professional with more than 12 years of management experience steering and directing the operations of various manufacturing environments. Intuitive leader inspiring high productivity levels; repeated success guiding sizeable cross-functional teams as well as training, coaching and motivating staff. Strong quantitative and analytical skills. Extensive knowledge in developing, evaluating, and implementing continuous process improvements eliminating waste and reducing cost while maximizing yield. Excellent communicator, successful at establishing and maintaining productive relationships with direct reports, senior management and building cohesive teams focused on safety, quality and production goals.

Core knowledge & Skill areas

A.C.E. Gold Certification Total Productive Maintenance Process Certification

Value Stream Mapping Quality Control Process Chart Passport Review Process

Production Preparation Process Setup Reduction Market Feedback Analysis

5S Standard Work Visual Factory

Total Quality Management Kaizen Good Manufacturing Practices (GMP)

Professional experience

Clondalkin Pharma & Healthcare, Indianapolis, IN 2012

Plant Manager

Maintain the oversight of the entire Indianapolis facility. Oversee labor/management relations including: establishing and enforcing policies and procedures for operations, establishing training, recognition, and rewards programs, and assuring health and safety requirements are met. Manage all operations processes, and production work for the facility. Accountable for achieving performance objectives and product quality.

Selected Accomplishments

Played a key role in a kaizen event that reduced machine setup time by 80% and improved machine throughput by more than 200% (throughput went from 16,000 pieces/hour to 40,000 pieces/hour)

Reenergized a struggling 5S program that resulted in improved process flow and employee engagement

Machine setup time was reduced

Material handling presentation improved

Improved operator safety and ergonomics by decongesting the work space and reducing walking distance and wasted motion.

Developed a process to create a scheduling system for the finish product tray assembly.

Eliminated the waste of overproduction

Created a new material delivery system that reduced part storage areas by 50%, eliminated double handling of material, and improved ergonomics

UTC Carrier Corporation, Indianapolis, IN 2002-2012

Production Manager (2002-Present)

Directed the daily operations of the High Efficiency Fan Coil manufacturing cell, driving continuous process improvements to ensure excellent quality and outstanding output. Directly managed eight supervisors and 395 union employees. Ensured adherence to strict safety guidelines. Aligned staff and associates with workflow requirements: provided teams with up-to-date operational information in a vigorous environment.

Selected Accomplishments:

Received an -Exceptional Performance- rating on the annual performance review with upper management.

Continued

John A. Lilly page 2

317-***-**** / 317-***-**** / *********@********.***

Played a key role in initiating and driving strategies and processes (i.e. 15 kaizen events, 6 VSM events, 2 Production Preparation Process events, continuous RRCA, et.al) that resulted in the manufacturing cell achieving ACE -Gold- certification. An achievement that signifies -best in class-.

Continuous TPM and RRCA events

More than $500,000/year cost savings

100% reduction in WIP inventory

56% improvement in scrap cost

Additional savings in supplier part packaging

12% improvement in schedule attainment (yearly average improved from 89% to a sustained 101%)

68-86% improvement in product first pass yield

44% improvement in warranty claims

99% of production process converted to one piece flow method

Developed a department engagement team that allows union employees the opportunity to work with management and cross functional groups to improve associates` training, performance, efficiency, and ergonomics.

Streamlined processes and improved training and staff utilization to reduce manpower by 5%.

National Starch Food Innovations Inc., Indianapolis, IN 2000-2002

Production Shift Supervisor (2000-2002)

Supervised the daily operations of multiple departments that functioned dependently of each other to chemically treat, process, dry, package and store modified corn starch. Planned and coordinated job assignments to maximize production and quality standards, implementing creative strategies when required. Analyzed chemical treatment issues and advised process operators of corrective actions.

Selected Accomplishments:

Pursued, received and completed specialized training to become a certified Industrial Medical Technician, HAZMAT First Responder, and an incipient fire fighter.

Contributed to the development and implementation of an equipment specific lockout/tagout manual for departmental and mechanical safety as well as reducing production downtime.

Conducted daily safety awareness meetings with direct reports.

Performed daily and monthly GMP inspections to ensure compliance to standards.

Heritage Environmental Services/Micronutrients, Indianapolis, IN 1997-2000

Shift Supervisor (1999-2000) / Senior Chemical Operator (1997-1999)

Assisted in the management of all plant operations including personnel supervision, training, planning and implementation of effective methods for improving production quality and throughput.

Selected Accomplishments:

Evaluated and restructured standard operating procedures for reclaiming and crystallizing copper, improving product quality and daily production increased by a margin of 25-50 percent.

Assumed the responsibilities of an ISO 9002 Quality System Internal auditor. Conducted quarterly audits to enforce compliance to standards that assured high quality products for customer satisfaction.

Developed and implemented a process recovery procedure that minimized lost production that resulted in over a 75% reduction in process downtime.

Worked with senior management as an employee liaison to develop an emergency contingency plan for plant evacuation and improve overall employee safety.

Education & training

Bachelor of Science, Environmental Science & Technology - University of Mobile, Mobile, AL

Professional development

Lean Manufacturing / Talent Development / Process Improvement

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