Shane Sumners

Education Address

Tennessee Technological University 1035 Richards Road NE

B.S. in Industrial Engineering - Minors in Math & English White, Georgia 30184

Overall GPA - 3.5 GPA in Major - 3.7 Cell 770-***-****

ASQC Certified Quality Engineer # 23873 email – ac0160@r.postjobfree.com

Georgia Tech School of Management

Extensive Training in ISO 9000, Team Building, Kaizens, Toyota Production System, Lean Manufacturing,

SPC, Automotive Requirements, 5S Housekeeping, SMED, Management

Experience

Chief Operating Officer & Partner (12/2014 to present)

SBJ Recycling, MidState Plastics & GreenSheet Extrusion – (Recycling - a leading recycler of waste and excess material streams including ABS, PP, PE, PVC, TPE, TPO, Nylon, LDPE, EVA, PS, HDPE, etc... SBJ Recycling services include toll processing, shredding, grinding, baling, extrusion, pelletizing, materials recovery and separation, sheet extrusion, etc... SBJ Recycling utilizes company trucks and trailers for pickup and delivery including dropped trailers.)

Responsible for all aspects of business – sales, manufacturing, purchasing, financial, HR, IT, distribution, etc.…

Developed new customer relationships for increased sales and profitability growth

Negotiated sales, toll processing, and purchased product prices

Refined extrusion operations with process controls and lean manufacturing

Led startup of new sheet extrusion business with new customer base and new equipment in 2nd plant

Led business plan development with increased emphasis on toll processing

Managed company finances and banking relationships

Negotiated reduced cost policies for Workers Compensation, Property, Business Interruption, Liability Insurances– implemented initial company health insurance plan

Implemented inventory control and production control / scheduling procedures

Purchased and implemented several pieces of new equipment to expand manufacturing capabilities and business opportunities – modified plant layouts for efficient product flow

Developed Human Resources and administrative policies and procedures

Enhanced Safety program with many new safety procedures and equipment

Experienced with shredding, grinding, extrusion pelletizing, extrusion sheeting, baling, waste disposal, etc.…

Chief Operating Officer (7/2006 to 12/2014)

Apache Mills Inc. – (Mat Supplier – Retail, Commercial, and Industrial Matting and associated products). Apache Mills Inc. is one of the world’s largest suppliers of matting products and is privately owned.

417 South River Street, Calhoun, GA 30701

Apache Mills Inc. manufactures and distributes all types of mats – indoor, outdoor, kitchen, bath, industrial, anti-fatigue, car mats, truck flooring, rugs, etc… to a variety of customers. The largest sales segment is to large retailers such as Wal-Mart, Home Depot, Lowes, Target, Costco, SAMs, Sears, Kmart, Menards, Kohls, Garden Ridge, etc… The commercial segment sells to major catalog companies such as Global, Fastenal, MSC, McMaster Carr and Grainger as well as many other distributors and Janitorial suppliers. The Industrial division sells to tier 1 automotive suppliers and other industrial customers. Apache exports matting products to many countries over the world. Apache produces products in PVC vinyl and foams as well as recycled raw materials such as crumb rubber (reground car tires). Apache Mills new Rug Division was developed and starting up in plant 4.

Responsible for all manufacturing, distribution, HR, safety, engineering, maintenance, inventory control, production control, new production implementation, purchasing, etc…

Worked with the entire company team to expand company growth via expansion in operational and manufacturing capabilities and increased profitability by increased efficiency, new processes, information technologies, distribution, and product development of new products to an increase of $85 M in sales and up to 600% in increased EBITDA

Assisted in product line expansion into Kitchen mats, Bath mats, Car Mats, Rugs and Recycled products

Installed numerous additions in capital equipment such as several rubber molding presses, flocking processes, molding presses, increased heat transfer processes, digital printing, foam molding, regenerative thermal oxidizer, tufting machines, auto rollup machines, and extrusion.

Led company acquisition and integration of Royal Manufacturing --- expansion to 2nd manufacturing and distribution plant location

Responsible for all Manufacturing Operations, Engineering, Tooling, Human Resources, Purchasing, Production Control, Research & Development, Quality, Packaging, Environmental, and Distribution

Responsible for duties of up to 800 production associates

Expanded operations form one plant to four plants in Calhoun Georgia with over 1 million sq. ft.

Assisted in the startup of a rug division with tufting machines, auto rollup machines and supporting equipment

Led expansion of supplier base and new purchasing procedures to reduce raw materials cost

Led reduction in labor cost by 25% + by method work and sound industrial engineering techniques

Increased ISO certifications to new plants and operations

Led development and start up of new extrusion operations (internally developed and installed) to produce retail matting from recycled materials with 95%+ recycled content which dramatically improved profitability of all extruded backed mats

Led purchased raw materials cost reduction projects for plasticizers, resins, misc. chemicals, binder, boxes, pallets, labels, etc…well in excess of several $1,000,000. Negotiated pricing and terms for many items.

Assisted in technology improvements working with IT department particularly in distribution from hand written BOLs to more user friendly operations. Assisted in scanning efforts from zero to company-wide scanning of inventory

Improved crumb rubber mat molding processes for increased efficiency and lower cost. Installed several new press lines and replaced previous crumb rubber process.

Developed foam mat molding and die cutting processes and installed several molding lines for new products

Led implementation of new digital printing equipment on foams and fabrics for new products. Improved screen printing lines and die clicking operations for increased efficiency and capacity

Implemented Narrow aisle racking with wire in ground for distribution center to store 5,600 pallets

Led purchase and installation of Regenerative Thermal Oxidizer to capture and destroy emissions from 4 Vinyl oven lines. Resolved EPA emissions concerns and improved oven air flow for greater processing efficiency.

Developed structured Human Relations department with new hire packages, temporary service programs, written HR procedures, formal job descriptions and wage scales

Improved production control and scheduling procedures to handle over 18,000 SKUs annually with approximately 350 SKUs of over 10,000 pieces and 6,500 SKUs of 10 pieces or less

Conducted two full physical inventory counts per year and developed cycle counting procedures

Experienced with vinyl ovens – solids and foams, compounding, rubber presses, flocking, heat transfer, tufting, cutting, screen printing, digital printing, rolling, packaging, and distribution

President and C.O.O. (10/2002 to 7/2006) began work at Snapper in 9/94 – (9/1994 to 7/2006)

Sr. Vice President of Operations & Engineering (7 yrs prior to becoming President)

Snapper – now Briggs& Stratton - (Outdoor Power Equipment – walk & ride-on lawn mowers, commercial mowers up to 73”, tillers, snow blowers, utility vehicles, vacuums, blowers, brush cutters, etc..)

535 Macon Road, McDonough, GA 30253

Snapper manufactures, distributes, and sells a large variety of outdoor power equipment primarily through a large number of independent retailers. Snapper has sold through various mass retails like Home Depot and Wal-Mart in the past and currently is a contract manufacturer for John Deere through Lowes and the Deere dealer network. Snapper also sells internationally to over 35 countries. The Snapper operations include Giant-Vac debris products including vacuums, blowers, brush cutters and truck loaders. Snapper produces over 2,500 finished units per day.

Led company through two purchases Simplicity Mfg Inc. 10/02 and Briggs & Stratton 6/04

Led company to exceed annual business plans each year by 15% to 25% in net income and EBITDA

Responsible for all Distribution, Call Center, Credit, Inside Sales, MIS, Giant-Vac Sales and all Operations & Engineering functions including: Fabrication & Assembly, Quality, Safety, Production Control, Purchasing, Maintenance, Tool Room, R&D, Security, Design Engineering, & Testing.

Responsible for duties of 700 Mfg. bargaining unit associates (USWA with 47% membership) and up to 160 salary associates in focused factory concept with 5 Fabrication areas and 9 assembly lines reduced grievances from 200+ per year to less than 10 per year

Responsible for operations and product design for sales primarily through 5,000+dealer network and various mass retailers at times including Home Depot, Wal-Mart, and Lowes (contract for Deere); and $20M to $25M parts business

Responsible for 465,000 sq ft of manufacturing floor space with nine assembly lines, stamping operations up to 1000 ton, robotic welding, CNC and multi-spindle machine, CNC press brakes, laser operations, and finishing systems with both powder and ecoat; and distribution facilities over 600,000 sq. ft. in Georgia, Texas, Ohio, and Nevada

Led Mfg. transition to more JIT production system as field inventory was reduced from $200M to appx. $40M and 52 distributors were eliminated as Snapper went dealer direct to 5,000 dealers – built in house company call center for 40 associates to service all customers

Led operations team to reduce total operations variances from a $10M to $35M range in previous eight years to positive variances in 1997 - 2002 and then to significantly positive variances from 2002 to current

Coordinated move of Giant-Vac manufacturing operations from Connecticut facility to Snapper McDonough

Managed seasonal manufacturing seeking to level labor requirements and led improvements in Mfg. direct labor efficiency form (50%-70%) to (110%-120%); led to significant reductions in the number of bargaining unit associates

Led reduction in safety recordable rate to less than 7 and workers compensation cost to approximately $100,000/yr or less

Managed Union negotiations for two 3 year contracts and one 5 1/2 year contract under budget; self insured healthcare conversion and plan benefits restructuring; reduction of Union grievances from over 200/yr to appx. 22/yr

Directed start up of three new product assembly lines and complete restructure of other lines in addition to many new models of existing product; Led start-up of Commercial products division to $25M to $30M business

Led effort to improve supply base (75% zero defect) and begin overseas sourcing of component parts

Established state-of-the-art call center with integrated functions of order processing, credit, data management, with dealer portal for orders and credit check etc…

Championed cost reduction efforts through vertical integration of outside processes such as 3 CNC Machining centers, 3 CNC press brakes, 4 laser purchases and 8 robotic welders; design related cost reduction kaizen teams over $1M/yr; purchasing alternate suppliers and multi-year agreements $2M/yr, direct/indirect labor savings, etc…( Approximately $20M in documented cost savings since 1997)

Implemented ISO 9000 based quality system with structured procedures & work instructions on network

Led reduction efforts on scrap of 85% and warranty cost of 70%

Led implementations of timeline management, ECR/ECN procedure, manufacturing measureables/tracking, variable rate scheduling by model, balanced work force, housekeeping audit system, 99%+ part sales fill rate plan, line balancing, departmental budgeting and controls, JBA enterprise software system, USWA union negotiations, design and mfg. kaizen teams, set-up reduction, robotic welding, etc…

Experienced in sheet metal forming/stamping 60 to 1000 ton, welding, machining, painting E-coat & powder, JIT assembly, one piece work flow, kanaban racks, and andon systems

Quality Manager, C.Q.E. / Manufacturing Manager (8/91 - 8/94)

Fayette Tubular Products – A Danaher Company - (Tier one automotive air conditioning tube and hose assembly supplier for Chrysler, Honda, Ford, GM, Jaguar, Valeo, BMW, Zexel)

P.O. Box 100 Hwy. 85, Livingston, TN 38570

Responsible for all Quality functions - Supervised inspectors, auditors, engineers, & technicians

Responsible for ISIRs, control plans, SPC, lab durability testing, gage control, part layouts, customer/internal corrective action plans - 8Ds, 5 Whys, & CARs, advanced quality plans, customer surveys, etc…

Led self-certification status with Chrysler, Honda, Valeo, & Zexel

Led customer returns reduction effort from 5000+ppm to under 150 ppm based on rolling 13 month average

Implemented Quality systems, procedures, & controls to exceed all automotive standards (QS 9000 based )

Led automotive platform launch teams and initial runoffs

Managed plant activities when required in plant manager’s absence

Developed state-of-the-art leak detection methods with helium mass spectrometers

Experienced with JIT manufacturing, regular Kaizen activities, poka-yoke, & Kanabans

Experienced in aluminum/steel/copper tube bending, painting, cutting, brazing, welding, endforming, hose crimping & assembly

Manufacturing / Quality Engineer (1/90 - 8/91)

TRW Steering and Suspension Division (Tier one automotive supplier for Chrysler, Volkswagen, Nissan, Hyundai,)

2101 West Main Street, Rogersville, TN 37857

Responsible for quality systems in 4 departments - rack tube, valve sleeve, input shaft, & valve assembly

Supported day to day issues on manufacturing floor with quality issues and machine problems

Developed design changes to reduce cost and improve quality

Developed outgoing audit system, gage calibration & control system, scrap tracking and reduction program, computerized SPC for appx 100 key characteristics, and inspection instruction sheets

Developed Failure Mode Effects Analysis and Process Control plans for all parts in departments

Completed ISIR packages for customers and resolved customer/supplier problems and warranty issues

Responsible for capital equipment acceptance criteria, specifications, and machine trials

Completed tool life studies and experiments to determine best tooling for drills, mills, and screw machines

Assisted in cost reduction kaizens to improve methods and large capital expenditure implementation

Performed several DOEs ( Design of Experiments ) to resolve complex problems

Experienced with shearing, extrusion, welding, drilling, milling, honing, multi-spindle machining, valve balancing, assembly, etc…

Industrial Engineer (6/89 - 9/89) summer internship

Matthews Industries (produced chillers for Carrier Corp. and various other sheet metal type products)

PO Box 428 Decatur Alabama, 35602

Established initial work standards via time studies, improved operational methods, balanced fabrication/assembly line, developed smooth flow layouts, and installed unit cost on computer system for primary product line of chillers from 100 ton to 1200 ton ( primary project for summer completed in less than of estimated time)

Performed time studies, optimized work cell layouts and standard work for multiple other products

Developed cost savings based on operational improvements and method work

Experienced with shearing, piercing, sheet metal bending, rolling, assemble, machining, welding, etc…

Industrial Engineer (1/86 - 1/87 & 6/87 - 9/87)

Rockwell International (Aluminum Die Castings for multiple customers, also produced industrial gas regulators)

PO Box 440, Russellville Ky, 42276

Worked as IE co-op for one year in multiple departments to improve operation methods, maintain method/setup sheets, conduct incentive based time studies (hundreds); design reports for operations measureables; work sampling for fork lift truck utilization; worked on plant layout on AutoCAD; and worked on methods improvements for direct labor cost reductions

Designed and established initial JIT work cells for the plant

Developed training program and trained salary staff on Lotus 1-2-3

Assisted cost estimator in quoting new business by determining material cost and job routings

Evaluated, justified and installed large capital equipment such as die cast machines, robots, trim presses, and tooling

Due to vacancy, worked as responsible Industrial Engineer for multiple departments to implement JIT work cells, layouts, method improvements, time studies, capital projects, and maintain routine IE functions.

Personal Information

Happily married for over 25 years with two children

Excellent health

Hobbies include golf, youth sports, community activities, and rental properties

Primary management strategies include: solid attention to details and discipline on the basics of safety, quality, efficiency, inventory control, housekeeping, & cost reduction; well communicated and measured goals / projects, continuous improvement philosophy, JIT Toyota Production system, employee participation and empowerment

References available upon request.

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