Senior Operations Manager

James T. Maas

***** ***** *****

Abingdon, VA ***11

276-***-**** ******@***.***

SUMMARY

Senior Operations Manager with 27 years of extensive operational and supply chain experience.

Established leader in implementing lean production principles to increase operator efficiencies, improve

quality, and reduce capital investment. Well respected as a manager with superior system skills that

drives continuous improvement through the supply chain to improve the bottom line. A diverse

background of operations and supply chain core competencies that include:

Green Belt Trained Capacity Planning Pull Systems / Kanban

Lean Facilitation Poka Yoke Just-In-Time

Value Stream Mapping MRP Systems Key Performance Indicators

PROFESSIONAL EXPERIENCE

General Dynamics Armament & Technical Products Feb 2009 - Present

Senior Manager of Operations, Composite Programs (Marion, VA) Jun 2011 - Present

Reporting to the Senior Director of Operations, directs a staff of 9 salary and 100+ UAW hourly

employees. Complete operational oversight for safety, quality, delivery, cost, and continuous

improvement for the production of all composite programs. Site is a leading manufacturer of

aerospace and defense composite products and military shelters.

• Achieved 99.7 customer delivery performance in 2012

• Manufacturing hours per unit were 7.7% better than operating plan targets in 2012

• Reduced manufacturing defects by 8 percent in 2012

• Lead all manufacturing areas in Lean/Continuous Improvement initiatives in 2012

Senior Manager, Production Control (Marion, VA) Feb 2009 – Jun 2011

Reporting to the Senior Director of Operations, directed a staff with complete responsibility for all

Master Scheduling and Production Planning activities for three plants at Marion location. Site utilizes

Oracle MRP system for all planning functions.

• Increased customer delivery performance from 90% to 98%.

• Improved internal build plan performance from 55% to 80%.

Chrysler LLC, (Multiple Locations) 1985 – 2008

Manager, Adv. Supply for Powertrain Programs (Auburn Hills, MI) Aug 2004 – Nov 2008

Reporting to the Senior Manager in Advance Supply, directed a staff of engineers and contractors

with full responsibility for developing and implementing lean material delivery solutions for Chrysler

engine, transmission and axle plants. Team developed annual budgets and procured material

handling equipment to meet program timing and to exceed company goals in the area of safety,

quality, delivery and cost.

• Achieved capital investment reductions of $1.7 million in 2007.

• Developed lean solutions for future capital investment reductions of $3.7

million and annual transportation cost reductions of $3.5 - $5 million.

• Incorporated packaging concepts into up-front, simultaneous engineering

activities. Maximized opportunities to modify part designs for optimum container density while

ensuring the quality of the part through the manufacturing process. Reduced packaging costs by

$500,000 and improved operator efficiencies by more than 20% in several manufacturing areas.

Manager, Vehicle Plant Scheduling & Forecasting (Auburn Hills, MI) Feb 2003 – Aug 2004

Reporting to the Senior Manager for Vehicle Scheduling, directed a staff of management and

bargaining unit analysts in vehicle scheduling and forecasting for (8) assembly plants in the U.S.,

Canada, Mexico and Europe. Member of cross-functional team tasked with designing, developing,

testing and integrating a new MRP/ERP system (i2-Supply Chain Planner) with multiple Chrysler

mainframe systems.

• Reduced assembly plant re-schedules by 54%.

• Successfully facilitated the schedule of all early build out items at vehicle assembly plants, thus

driving out complexity and enabling a smooth transition to the next model year launch.

• Streamlined testing process for the new MRP system by reducing turnaround time by 60%.

Manager, Capacity Planning & Constraints (Auburn Hills, MI) Jan 2000 – Feb 2003

Reporting to the Senior Manager for Production Programming, directed a staff of 5 specialists

responsible for managing the material constraints for all Chrysler assembly plants in North America

and Europe. Analyze supplier processes, identify bottleneck operations and collaborate with

Purchasing, Sales & Marketing, vehicle platform teams, and the suppliers to optimize component

supply.

• Implemented multiple reporting tools to aid Supply managers in the decision process when

evaluating constraint management alternatives. Reduced analysis time by 25%.

• Reduced processing time of Capacity Planning reports by 40% each week.

• Integrated constraint data directly into the vehicle scheduling process which significantly reduced

the number of constraint scheduling violations.

Materials Manager, Mack Engine (Detroit, MI) Feb 1997 – Dec 1999

Reporting to the Production Control Manager, was responsible for inbound and outbound production

material for a $500M+ manufacturing operation. Manage staff of 6 material supervisors and 70 UAW

material handlers over 2 shifts and led the team that established the material control infrastructure for

the new engine plant. Collaborate with internal and external packaging engineers on all container

decisions for inbound production material and lean delivery.

• Championed efforts to achieve 100% JIT deliveries from the supply base to the engine plant.

• Effectively integrated manual delivery processes with automated guided vehicle (AGV)

processes.

• Authored much of the ISO 9000 documentation for the Production Control department,

enabling the plant to earn the ISO 9000 certification.

Team Leader, JIT Powertrain Logistics (Auburn Hills, MI) Oct 1994 – Jan 1997

Reporting to the Senior Manager of Supply, supervised 3 analysts responsible for the implementation

and management of JIT programs for Chrysler engine, transmission, stamping, and component

plants.

• Successful in identifying and correcting system errors causing $6 million in excess inventory.

• Implemented inventory system reporting tools to reduce analysis time by 25%.

• During tenure, increased JIT programs from 78% to 94%.

Supervisor, Inventory Control Systems, Trenton Engine (Trenton, MI) Feb 1993 – Sep 1994

Customs Specialist, Trenton Engine Plant (Trenton, MI) Jan 1992 – Feb

1993

James T. Maas

Industrial Engineer, Trenton Engine Plant (Trenton, MI) Jan 1991 – Jan 1992

Production Supervisor, Trenton Engine Plant (Trenton, MI) Jun 1985 – Jan 1991

EDUCATION

Masters Degree in Business Administration

Concentrations in Production Operations Management & Organization Behavior

Oakland University, Rochester, MI 1997

B.S. Degree in Supervisory Management Technology

Purdue University, West Lafayette, IN 1985

PROFESSIONAL TRAINING

Green Belt training completed in March, 2011 through BMGI

MRP Systems

Lean manufacturing

Value Stream Mapping (VSM)

Statistical Process Control (SPC)

Total Supply Chain Cost Analysis (Transportation, Packaging, and Purchasing)

Proficient with MS Suite (Word, Excel, PowerPoint, Project, Visio and Access)

INTERESTS AND OTHER ACTIVITIES

Smyth Career and Technology Center Advisory Committee (2013 –present)

Toastmasters International

o President, Speaking Dynamically Club in Marion, VA (2010 – 2011)

Rochester Hills Little League, Rochester, MI

o President (2007)

o Board of Directors (2003 – 2007)

o Baseball & Softball Manager/Coach (2000 – 2007)

o Outstanding Volunteer Award (2004)

North Fairview Farms Homeowners Association Rochester Hills, MI

o Board of Directors (1998 – 2001)

PERSONAL INFORMATION

Married for 22 years with two children, son (21) and daughter (19)

Willing to relocate

Willing to travel

James T. Maas

Contact this candidate