Manager Six Sigma
Resume:
Joseph McCaleb
August Leaf Dr
Tomball, TX 77375
********@*******.***
VP/Manager, Manufacturing/Fabrication
Summary
VP/ Manager-Degreed
Manufacturing and Fabrication Management Professional. 30 years of
experience. Skilled in the areas of Plant Management, Operations, and
Project Management. Well versed in Business Strategy and Planning. Expert
in improving work flow and production output to improve any organizations'
Bottom-Line. Have managed up to 90 personnel. Have managed and designed
projects up to 35 million in scope. A no-nonsense Manager who knows how to
get the most from any production process.
Core Competencies
Expert in Manufacturing Processes and Fabrication Operations. Extensive
Management, Supervisory, as well as Hands-on, experience. Extensive
computer skills including AutoCAD and ERP. A Champion of Lean
Manufacturing and Six Sigma practices. Skilled in a wide variety of
manufacturing situations and the ability to adapt to any kind of change
quickly and effectively. Able to forecast long term strategies and direct
operations to meet those goals. Education and experience in high speed
manufacturing as well as high skill, low volume fabrication. In depth
knowledge of fabrication machinery from hands on experience. Adept in
welding technology and ASME codes. Sheet metal expert. Highly skilled in
all areas of fabrication. From small job shop situations to large
construction and oil field projects for large corporations. Extensive
experience with contractors, outsourcing, and customer interaction. Navy
veteran of 4 years active, and 14 years reserve.
Work History:
Vice President of Manufacturing
Shield Air Solutions Inc., 3708
Greenhouse Rd Houston Texas 77084 PH: 281-***-**** 06/12 to 01/13
Directed all fabrication and assembly operations of the manufacturing of
industrial air conditioning units. Drove change to streamline production
processes. Taught Lean Manufacturing in a classroom setting to help change
the culture of this company. I arrived during the merging of two separate
companies in to one. Instituted cross training throughout the work force to
increase company versatility and to facilitate a smoother merging process.
Increased unit testing capabilities by adding 2 more testing stations, thus
doubling capabilities. Obtained another laser and press brake for the
fabrication shops thus doubling the laser capacity. Re-organized the layout
of the fabrication shop for better work flow and implemented visual
workplace throughout the entire shop. Implemented cell manufacturing
throughout all fabrication and assembly operations to eliminate wasted time
in searching for parts, tools, and material movement. Implemented the use
of Kan-Bans throughout the shop for all standard, stock components and set
up consignments from suppliers to keep them stocked. Re-organized the
painting process by clearing more room for drying parts and added 3 times
as many drying racks. This doubled our painting output. Eliminated all
clutter, old machinery, obsolete parts, etc., to give the shop more
production area. Attended Board and Senior Management Team meetings and
personally held morning production meetings with my direct reports on a
daily basis. Worked closely with the other members of the SMT to schedule
and maintain a steady work flow with high quality and customer
satisfaction. Managed 6 direct and 82 indirect reports in this position.
Due to company restructuring and cost cutting, the position in this company
was eliminated along with others. Not terminated. I was given a letter of
recommendation, severance pay, and a sincere apology.
. My manufacturing team and I increased production from 400K per month
to an average of 1.7 million a month in 7 months. It was my
responsibility to produce the production report on a monthly basis.
Fabrication Manager
Tps Houston Group LLC, 7101 John Ralston Rd. Houston TX 77044 PH: 281-459-
2435 11/06 to 06/12
Directed the fabrication of Generator Sets, Power Staions, and other
Skidded Packages for the Oil Industry. Performed the Designing,
Engineering, and Managed the fabrication of all components needed to
accomplish these projects. Met with the company President on a daily basis
to discuss planning and strategy. Interacted closely with customers to
fulfill their needs. Designated and ordered all materials and helped plan
other logistic issues. Quoted all jobs pertaining to fabrication. ERP
experience with Mapics, Syteline. Trained, tested and obtained
certifications for all welders. I managed up to 15 direct and 15 indirect
reports. I used Lean Techniques to streamline production and keep costs
down. Left because I was offered a VP position.
. Personally designed and built the largest Helicopter rig, Generator
set, Power stations ever built. They were built for hard to reach
jungle areas.
. Designed and laid out a 35 million dollar, fixed, power station for
the government of Ecuador. Ground-up construction.
. Designed and laid out a 23 million dollar, fully enclosed, Generator
set power station composed of 32 separate units that could be
assembled together on-site to form 2 large buildings.
. Launched the set up of, acquired certification, and put in to
practice the ASME program for this company obtaining both the "U" and
"R" stamps, thus enabling this company to produce pressure vessels.
. Collaborated with the president, on the designing and building, of a
power generation system that used 70% natural gas, 30% diesel.
Plant Manager
AAA Technology, Brittmoore Rd Houston TX. PH: 713-***-**** 09/05 to 09/06
Directed the fabrication, assembly, and testing, of Pipe Supports
(tensioning devices) for the oil refining industry. Drove and implemented
efficient and effective departmental processes, policies, and procedures
for the entire facility. This included welding, assembly, paint, shipping
and purchasing operations. I managed 4 direct reports and 25-45 indirect
depending on the work load. I left this position due to the unscrupulous
business practices of the owner.
Manufacturing Supervisor
Goodman Manufacturing, 610 Loop Houston TX PH: 713-***-**** 07/04 to 06/05
Supervised the manufacturing of furnaces and air conditioners on an intense
production schedule for 5 assembly lines. Supervision of a large
fabrication press department as well as a powder coat paint line. Drove the
implementation of new procedures utilizing Lean, Six Sigma, and Kaizen
techniques. Coordinated with the other supervisors, the physical layout of
machinery for maximum Lean efficiency as well as developed cost saving
procedures. Supervised from 20-60 direct reports at any given time. Reason
for leaving was too many hours required. 12-16 hr days, 7 days a week. I
needed to see my family.
. I was the first person in the plant to become Six Sigma Certified
. I was nominated as the Shift Safety Officer and enforced all safety
regulations throughout the plant.
. Decreased press set up time from over 30 minutes down to 8 minutes for a
complete die change over using SMED practices.
. Re organized the kanban system for the powder coat line to facilitate
faster loading and unloading of parts. This also minimized fork lift
travel times and increased our abilities to keep the assembly lines
supplied. This also enabled us to eliminate 3rd shift on the paint line.
Other relevant hisory-
Manufacturing Supervisor
W.H. Porter Inc. Holland Michigan. 1987-1997
Supervision of 1-10 people in the sheet metal shop during the entire course
of this ten-year employment. Utilized Lean techniques to streamline
production and efficiency.
Operation of shears, brake machines, presses, power tools, scheduling,
packing and loading of the product, coordination of scheduling with the
main office, production meetings etc. CNC as well as manual machines. All
shipping operations.
Worked closely with the engineers on design problem solving.
Built walk-in mobile freezer units for the U.S. military following govt
contract guidelines as well as prefabricated buildings. At the beginning of
this employment, we averaged 7-10 buildings per week. At the end, we were
producing 50 to 70 buildings per week. I made 678 freezer units in 5 years
averaging 5 per week.
Enforced safety and adherence to OSHA guidelines.
Hiring and firing of personnel
Made thousands of prefabricated buildings, park Shelters, gazebos, freezer
units, and other job shop jobs as required. Also made laminated panels for
all sorts of buildings.
More extensive work history is available upon request as well as
transcripts and recommendations.
Education- Total credits, 218
Bachelor of Science in Management, Almeda University, 2005
Business Management, 53 credits towards AS, Ashworth College, Enrolled
Professional Project Management Program, Ashworth College. Diploma
W/Honors, 2010
Auto cad Certification, Penn Foster Career School, 2009
Six Sigma Certification, Goodman Manufacturing, 2005
Lean Manufacturing Certification, Shield Air Solutions (Also taught the
course), 2012
OSHA Safety Standards, 24 hr course, Goodman Manufacturing, 2005
ASME Section VIII, Div.1 Seminar, Bureau Veritas, 2007
Military: 4 yrs active Navy, 14 yrs Navy Reserve. Awards: Navy
Expeditionary Medal, Sea Service, Meritorious Unit Commendation, Battle
"E", Humanitarian Service Medal. 31 Credits in Navy training courses and
schools. Transcript available as well as honorable discharges.
E-5 Bosn' Mate - USN, 4yrs: Seamanship, Rigging, Transfer at sea
operations, Weapons, Boats, Fire fighting, Leadership and conducted
training, Planned maintenance systems, Mooring, Ship Maintenance, Helo
operations, Navigation, Pilot house operations and security.
E-5 Bosn' Mate- USNR, 8 yrs: Same as above as well as Master at arms
duties.
E-5 Steelworker, Navy Sea Bees- USNR, 6 yrs: Welding and machinery
maintenance. Trained in accomplishing these duties under combat conditions.
Weapons. Leadership and conducted training.
Summary:
30+ years of experience. Fabrication Expert. Leadership roles of up to 90
people. Management, Supervision, Estimating, Quoting, Designing,
Construction, Installation, Fabrication. Total Quality Management, Project
Management. Manual and Computer Drafting. Steel layout and fabrication
expert. Extensive leadership experience and training. Human Resource
Management. Seamanship. First aid and Safety. Fire fighting. Accounting.
Lean/Six Sigma. Windows, Office, Autocad, Mapics, Syteline, Kronos, Turbo-
cad, Project. Welding, mig, tig, stick, and fluxcore. Forging. Artistic
ironwork. Sheet metal up to heavy architectural. Presses up to 600 tons.
Brakes, shears, roll formers, turret punches, saws, and most machinery
involved in fabrication. CNC as well as manual. Overhead Cranes, and Mobile
Cranes up to 60 tons. Tractors, Trucks, Boom trucks, Lifts, Forklifts,
more. General Maintenance on all the above machinery. Pipe welding.
Structural welding. Specialty Welding. Skids, Platforms, Onshore,
Offshore. Pressure vessels. Sheet metal expert. I have been around the
world and have experience with many different foreign nationals. I have
designed and built projects from small job shop work to 35 million dollar
power stations. Much more...
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