JOHN M. MONROE

**** ********* ******, ********, ** 29505

(H) 843-***-**** (C) 843-***-****

ac0vxt@r.postjobfree.com

LEAN MANUFACTURING MANAGER / PLANT MANAGER

Highly skilled manufacturing professional with proven operational and management experience specializing in strategic planning, project management, operations improvement, production efficiency, and motivational team leadership. I have strong working knowledge of “Lean” manufacturing principles along with Six Sigma Greenbelt training. Hands-on manager and critical thinker who can quickly grasp, analyze, and interpret complex concepts and develop them into logical strategies to produce immediate contributions to business operations.

PROVEN AREAS OF EXPERTISE

Operations Planning

Start-up & Turnaround Operations

Constraint Management

QS9000/ISO/TS16949

Lean Manufacturing

Kaizen Activities

Six Sigma

Cause-Effect Problem Solving

Key Performance Indicators

High-Tech Manufacturing

P&L Operations

Motivational Management

PROFESSIONAL EXPERIENCE

SCHAEFFLER GROUP, South Carolina Bearing manufacturing

Business Unit Manager 11/2012 – 02/2015

Managed 250 person business unit within a 850 person plant. Responsible for new product launches in segment including hiring and training programs. Processes include cold draw, wire hacking, heat treat, grinding honing and grading.

Implementation of flow-line processes to reduce changeovers and maximize grind wheel life.

Restructure and development of technical training methods

MAGNA INTERNATIONAL, Clinton, TN Metal stamping

Business Unit/CI Manager 01/2010 – 11/2012

Manage about 350 person assembly operation on a 24 x 5 schedule. Processes include welding, robotic welding, spot welding in structural body component assembly. Tier 1 supplier to GM, Ford, Chrysler, Toyota, Nissan, SIA and Honda for body structural components (A-pillar, B-pillar, roof rail, and door sill assemblies)

Implementation of new training process (TWI) to add standardization to processes and setups.

Building expansion program for 130,000 sq. ft. addition for new product and current product flow improvements.

STARBUCKS COFFEE COMPANY, Sandy Run, SC Coffee Roasting Plant

Senior Process Manager 08/2007 – 08/2009

Hired as member of Greenfield start up plant leadership team for $80M coffee roasting plant in SE area. Set up operations for 24/7 manufacturing process including hiring process, training, and machine commissioning. Processes include roasting, high speed packaging operations, and automated (robotic) palletizing operations.

Worked with startup team and applied Lean/Six Sigma/Value stream tools used in overall plant layout and design.

Managed and coordinated AIB, GMP and HACCP training and orientation for processing team members.

Trained and educated all employees, contributing to plant profitability stage in first 8 months of operation.

HITACHI AUTOMOTIVE GROUP, Monroe, GA Automotive Parts

Production Manager/Safety Manager 03/2005 – 07/2007

Managed 110 manufacturing employees in engine component plant. I also had Plant Safety and Environmental responsibilities. Processes included machining, welding, paint, injection molding and assembly.

Decreased cost by increasing efficiencies 8.6% and reducing scrap to 0.4% through Lean practices.

Applied 3-Gen Shugi and PDCA methodology throughout plant which expedited root cause analysis.

Completed certifications for TS 16949 in 2005 and ISO14001 in 2006.

JOHN M. MONROE Page 2

GREENPAK INC. Florence, South Carolina Metal Packaging

Plant Manager 12/2003 – 12/2004

Managed a welding and fabrication facility producing large returnable metal containers for Honda ATV plant locally. I was responsible for all operations of plant including full P & L of facility. I managed about 125 team members in achieving new product start-ups and successful product launches for a retooled plant.

Increased sale from $850,000/mo to $1,420,000/mo through enhanced quality and delivery to customer

Reduced D/L by over 50% through constraint management tools

Increased Operating Income by 400% with increased sales and decreased labor

CRENLO INDUSTRIES – DOVER CORP, Florence, SC Agricultural Cabs

Manager, Shop Operations 03/2001 – 11/2003

Managed all manufacturing operations of 250,000 sq. ft. facility producing ROPS (roll over protection systems) for the Ag industry. Process included stamping, forming, lasers, welding, fabrication, paint and assembly facility. Responsible for team development and team building practices at all levels of plant. Directed eight supervisors and 145 team members to achieve company objectives and goals in plant turn-around.

Implemented poka-yoke devices on weld fixture to eliminate about 40% rework.

Partnered with Caterpillar to implement Six Sigma strategies, which improved product deliveries.

Gained 15% efficiency through constraint management and line balancing techniques

DANA CORPORATION, Various USA locations Automotive Parts

Manufacturing Manager 11/1985 – 02/2001

Managed all plant manufacturing operations, including budget, for facility producing axle components and CV joints for Mercedes-Benz, Ford, and Chrysler with a sales volume over $55 million. Responsible for all aspects of CNC manufacturing, purchasing, customer service, and shipping. Supervised 225 personnel on 24/5 schedule.

Manufacturing Manager

Directed plant operations on a 4-shift, 7-day week program. Managed staff of about 225 people including purchasing, customer service, manufacturing (stamping) and shipping departments. Managed budget and strategic planning.

Process Engineering Manager

Recruited to assist in the full start-up of a new gasket and seal plant operation. Led groundbreaking operations, established equipment specifications, managed purchases, performed installations, and trained all operation personnel.

Manufacturing Engineer

Recruited to lead manufacturing operations of a 350-employee gasket and seal plant with a customer base including GM, John Deere, Caterpillar, IH, and Ingersoll-Rand. Processes included stamping, forming, compression molding, and various coating operations. Spearheaded all new equipment justifications, purchases, and installations.

CATERPILLAR TRACTOR CO. Joliet, IL Hydraulic parts & assembly

Various positions 1976 – 1983

Completed 4-yr Manufacturing Management training program with an accommodation.

EDUCATION / PROFESSIONAL DEVELOPMENT

Bachelor of Science, Business Management, Saint Regis University, Mead, WA 1992

Associate of Science, Manufacturing Technology, Oakland College, Pontiac, MI 1988

Six Sigma Green Belt Training - Crenlo/Caterpillar, Florence, SC 2004

Excellence in Manufacturing - Toyota Production Systems Training –Facilitator 1988

8000 hr Apprenticeship Program – Caterpillar Tractor Co. 1983

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