Michael R. Sykes

Cincinnati, OH ***** 469-***-****

www.linkedin.com/in/michaelrsykes ac14zx@r.postjobfree.com

OPERATIONS MANAGEMENT

Plant Management Continuous Improvement Process Improvement Supply Chain Management Lean Manufacturing

Total Productive Maintenance (TPM) Integrated Work Systems (IWS) Toyota Production System (TPS) 5S

Continuous Improvement and Operations Leader with high passion for winning with integrity while developing individuals and organizations to deliver a step change in sustainable results. Drives waste elimination, improved process reliability and reduced cost by extensive practical application of proven continuous improvement methodologies impacting the entire supply chain. Role models collaboration and servant leadership while utilizing strategic agility, complex problem solving strengths

SELECTED HIGHLIGHTS

Practical application of IWS/TPM in large, highly complex manufacturing facilities and networks

Led global effort to rollout Run to Target/Accelerated IWS across 50 sites

Delivered best in class process reliability of 86.4% and 190 MTBF

Achieved $47 Million supply chain loss elimination

Site leader for manufacturing plant and 2 distribution centers for 5 years

Transformed site culture to personal responsibility and solution oriented

Miraculous startup of Folgers plant 3 weeks after hurricane Katrina

PROFESSIONAL EXPERIENCE

YOUR ENCORE – Cincinnati, OH

Continuous Improvement Expert / Supply Chain Consultant (2016 – Present)

Provide waste elimination and systemic increases in efficiency, productivity, and profit for clients in varied industries

PROCTER & GAMBLE/MARS INC. (Acquired by Mars Inc. August 2014)

Plant Manager – Dry Pet Care Manufacturing and Distribution Center, Aurora, NE (2011 – 2016)

Led a step change in personal safety, food safety, customer service, operational excellence and cost utilizing IWS/TPM for site with 140 associates and 70 distribution center contractors

Achieved zero loss time injuries, zero micro detects, and 99% service while significantly raising engagement

Attained 90% culture survey score with 20% increase

PROCTER & GAMBLE – CINCINNATI, OH

Associate Director – Household Care Corporate Office, Cincinnati, OH (2008 – 2011)

Officer of the company with responsibility for increasing manufacturing capability and coaching plant managers at 13 facilities in North America and for development and deployment of Global strategies across 50 sites

Led the Integrated Work Systems (IWS) renewal in North America incorporating Toyota Production System and Lean Manufacturing tools including Run to Target and Standardized Work

Advanced 3 sites accountable for 20% of P&G profits to IWS phase 3 capabilities

Operations Manager (Pringles) – Snacks Manufacturing, Jackson, TN (2007 – 2008)

Led 250 person complex packing organization with 15 direct reports delivering best in class IWS for North America

Created a continuous improving culture utilizing IWS and lean manufacturing tools

Led effort that identified and eliminated $47 Million of losses

Operations Manager (Coffee) – Snacks & Beverage Manufacturing, Sherman, TX (2005 – 2007)

Led lean implementation and value stream improvement utilizing 5S workplace standardization, visual workplace tools, and high performing teams. Qualified as site HR Manager

IWS/TPM Site Program Manager, Cincinnati, OH (2002 – 2004)

Excelled as IWS leader of complex and dynamic organization with an annual operating budget of $35 Million and 200 technicians

Produced 96% reduction in breakdowns, minor stops, and quality defects

Increased technician productivity 95% and reduced overall case cost 25%

Generated solid base results in safety, quality, reliability and customer service

IWS Consultant – Snacks & Beverage Corporate Office, Cincinnati, OH (2000 – 2002)

Responsible for IWS/TPM implementation across three facilities. Also led the development and deployment of corporate strategies across the network

Increased market share while executing $200 Million consolidation

Operational Group Manager – Snacks & Beverage Manufacturing, Sherman, TX (1997 – 2000)

Directed two processing departments and one packing department. Responsible for all manufacturing results including cost, safety, product quality, delivery, and people development (190 technicians and 10 managers)

Previous experience included operations positions at P&G with increasing responsibility for budgets up to $25 Million. Selected accomplishments include:

Delivered a 30% process reliability improvement while implementing an Integrated Work System in a high performance site

Responsible for the transition to a future state that included $40 Million in capital spending, 200% capacity increase, high performance work system implementation, and conversion to a 12 hour shift 7-day rotation

Met all production commitments during conversion from 5 day to 7-day operation while integrating 30% new technicians into organization

Decreased department’s OSHA total incident rate by 70% in 10 months

EDUCATION

Bachelor of Science (BS), Electrical Engineering

Purdue University, West Lafayette, IN

National Merit Scholar

Phillips Academy Preparatory School, Andover MA

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