Plant Manager

ROBERT J. HAYS

*** ******** ***. ******** **, *0178

Mobile: 815-***-****

E-mail: ***********@*****.***

Summary

Professional Manufacturing Operations manager with expertise in leading

businesses experiencing rapid change, competitive market conditions, and

the need to meet challenges with limited resources. Results-driven,

experienced in use of Lean Sigma practices and employee involvement to

deliver improvement in operations.

Education

Judson University Elgin, IL

BA Management/Leadership

Professional Accomplishments

Tempur Sealy International (Formerly Sealy Mattress) August 2000 to

Present

(Sealy is the world's largest manufacturer of bedding products)

Director of Manufacturing / Business Unit Manager

. Batavia, IL ($100m in sales, 212k sq ft facility) July 2008 to

Present

. Saint Paul, MN ($43m in sales, 93k sq ft facility)

August 2005 to July 2008

. Responsible for Leading 2 separate manufacturing plants within one

Sealy Bedding facility, including Area Border Quilt Center,

Maintenance, Mattress and Box spring production, purchasing, customer

service, scheduling, order entry, delivery, human resources,

accounting, CI and quality.

. Lead design and start up of Area Quilting Center.

. Leader for 2 P&L's, budgeting, achievement, forecasting, and

corrective actions via Policy Deployment.

. Utilize Lean Sigma manufacturing processes to improve overall

efficiencies, including changing plant from two shift to one shift

operation while improving productivity.

. Lead eight managers and 4 office staff to direct 156 union production

and delivery employees.

. Manage Logistics for incoming freight and delivery finished product.

. Experienced in union contract negotiations and grievance resolution

(Steelworkers, Laborers, Teamsters)

. Established Corporate Best Practice utilizing Lean Sigma events to

improve sewing productivity, shipping efficiency and scrap reduction.

. Sarbanes-Oxley implementation, compliance and corrective actions.

. Achieved operations budget favorability of $781.1k against 2009

Budget.

. Achieved operations budget favorability of $465.2k against 2010

Budget.

. Achieved operations budget favorability of $321.6k against 2011

Budget.

. Achieved operations budget favorability of $306.3k against 2012

Budget.

. Reduced Working Capital from 42 Days on Hand to 17. (Saint Paul).

. Reduced OSHA Recordable from 53 in 2000 to 0 in 2007 using employee

Safety Committees. (Saint Paul)

. Member of New Product Launch Team and Manufacturing Advisory Board.

. Corporate Project leader for Boxspring Automation.

Resume of Robert J. Hays

Plant Superintendent, Saint Paul, MN August 2000 to August

2005

. Safety Coordinator and chair of Ergonomic Committee.

. Reduced corporate accident ranking from 22nd to 2nd using DuPont STOP

training.

. Reduction of Employer First Report of Injuries from 53 in 2001 to 6 in

2004.

. Lead Lean Manufacturing conversion from batch to one piece flow,

reducing hours per piece from 1.2 (2002) to .70 in 2005.

. Converted employee compensation plan from piecework incentive to MDW

(Measured Day Work).

. Firm understanding and application of Kaizen tools including Kanban,

DMAIC, 5S, 2P, TPM, 20 Day Projects, Value Stream, SMED, Department

Boards reviews, Value Stream mapping, Policy Deployment Reviews, Best

Practice Implementation, Vendor Corrective Action Request, and

Cellular Manufacturing through Rapid Continuous Improvement events

using employee teams.

. Hiring, performance reviews and progressive discipline for supervision

and Union employees.

. Participation in union contract negotiations and grievances.

. Liaison between operations and sales.

. Regional Perpetual Inventory implementation team Captain.

Cintas Uniform Corp, Schaumburg IL.

April 1992 to August 2000

(Cintas Corporation provides corporate identity uniforms and related

business services in the United States and Canada.)

Plant Manager June 1998 to August 2000

. Directed a 127 employee, 3-shift operation consisting of Maintenance,

Loading/Unloading, Production, Stockroom, and Washing departments.

. Controlled a $280k monthly budget. Responsible for monthly estimates,

Department P&L, annual projections, capitalization justification, and

vendor selection.

. Ranked 14th of 194 locations in overall expense for 1999.

. 5% rolling 12 month turnover was 2nd best in the corporation for 1999

and 2000.

. Attained 9% annual material cost versus goal of 15%.

. Team Leader of the Corporate Process Improvement Group.

. Assisted in facility acquisitions, purchases and shut downs.

. Responsible for hiring, performance reviews and terminations for all

Supervisors and hourly partners.

. Accountable for environmental compliance; class K wastewater operator

certified through the ILEPA.

Assistant Plant Manager

April 1992 to June 1998

Production Supervisor

Stockroom Supervisor

Sales Service Rep.

Hinckley and Schmitt Bottled Water, Elgin IL

Route Sales Representative September 1989 to

April 1992

Resume of Robert J. Hays

Awards and Recognition:

Sealy Mattress Company

. 2012 Materials Management Award

. 2009 Materials Management Award

. 2006 Continuous Improvement Gold Improvement Award

. 2005 Most Improved Safety

. 2005 Quality Plant of the Year

. 2002 Circle of Excellence

Cintas

. 1997, 1998, and 1999: "Rule 35" - based on growth, profitability and

Customer Satisfaction Index.

Professional Development:

Executec: Meticulous Hiring, Corporate Culture and Human Resources, Front

Line Leadership, Plant Manager College.

Zengler Miller: The Leader in all of Us, Operations Management,

Collaboration in the Workplace, Constructive Feedback, Ergonomics, Shop

Floor Management Training, Managing Change, Plant Manager Training

TBM: Lean Sigma Manufacturing Fundamentals. SKBIT

Simpler Consulting: Lean Manufacturing, Managing for Daily Improvement,

Value Stream mapping.

Safety-Net Inc.: OSHA Compliance & Safety Training.

Dale Carnegie: The Leadership Advantage.

Skill Path: The Essentials of Communicating with Diplomacy

Military

Illinois Army National Guard (Honorable Discharge)

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