Manager Plant

RUSS BARNES

**** ********* **.

Jenison, MI. ****8

Email: ****.******@****.*** Cell: 616-***-****

PLANT MANAGER/Operations Manager with 18 years of management experience in manufacturing operations, four years as a Plant Manager.

Skilled in:

Factory focus on Safety- focused on a dedication to ergonomics, safety teams and safety equipment

Business Management- promoting Lean Manufacturing methodologies, driving process improvements

Team Leadership -building effective teams through respectful communication across diverse styles and technologies

Talent Development- engaging and educating all employees, assessing and matching skill levels to appropriate job roles and creating a culture of accountability and safety

Plant Turn-Around and Recovery-through World Class Manufacturing methods and change management

RELEVANT ACCOMPLISHMENTS

Business Management

Targeted daily tasks and implemented electronic recording programs,(Lacks/Magna) that eliminated manual inputting of things such as production, scrap and key resets which eliminated 50% the time it took to record manually

Performed consistently under budget over four years in the start-up and growth stages of a state of the art assembly facility. Beat net income by 15% in 2009 and then in 2010 the plant was budgeted at a (178,000) but finished at +230,000

Budgeted and staffed assembly plant that grew from 30 work stations to 60+ assembly stations. Had 400+ individual jobs to assemble and did approximately $550,000 in sales each month (Lacks)

Successfully worked with companies, (Faurecia/CNI Plastics) to do multiple plant turn-arounds, bringing all WCM targets to green as well as change the culture for the team members.

Scrap control and reduction from $178,000 a month to $12,000 month over month. (Faurecia)

Drove assembly effectivity to a 13.5% improvement over 7 months. (Magna)

Quality Control

Worked to drive 18 month past due service orders for BMW to current through establishing team efforts and schedules. (Faurecia)

Personally represented Lacks assembly operations at customers for any quality issues or quality improvement initiatives, specific examples are Nissan and Ford. Participated at the customer to give corrective actions and was also the plant representative to the customers for internal audits of process

Recorded a 13% customer complaint improvement versus the metric (Lacks)

Implemented LPA systems in multiple companies up to the Plant Manager level. (Lacks/Faurecia/CNI/Magna)

Inventory Management

Reduced amount of mandatory 100% inventory audits from monthly to bi-annually by controlling scrap, level loading schedules and management involvement. (Faurecia)

Installed an electronic locater system at Lack’s to organize the warehouse which resulted in a 25% improvement on setup and changeover times, more efficiency at finding product, faster unloading and placement of product and more efficient at keeping count electronically

Responsible for the inventory accuracy annually as Plant Manager at Lack’s which held over a million dollars of inventory, came in at or under $15,000 to $20,000 negative

Successfully turned around the resin recycling in mold department that led to renewal of contract with the recycling company. Versus cancelation of said contract due to noncooperation of separating materials. (Magna)

Premium freight reduction of 97% due to schedule kaizen, staffing changes and production accountability (Magna)

Safety Management

Implemented ergonomic stretching exercises at Herman Miller for the assembly department.

As plant manager, received gold certifications from safety audits done by Lack’s Protective Services quarterly but also ensured that any minor findings that they had were assigned to responsible departments. Some examples would be unlabeled chemicals, product not banded properly on 3rd level of racks, emergency signs in place and visible, etc.

Participated in reviewing all jobs and machines that came into the plant for proper safety standards. Worked with engineering to establish standards for machines being built by outside vendors. Ergonomics heights, light curtains, guards, placement of PLC’s and monitors (Lacks/Faurecia/Magna)

Received facility-wide recognition for dramatically improving department safety incident rate, achieving a 17% overall reduction, the best performance over a 90-day period (Lacks)

Formal 5s system implemented all the way to the Plant Manager level.

WORK HISTORY

Magna International, Newaygo, MI

Business Unit Manager Assembly 2015 to Present

Business Unit Manager Molding 2014 to 2015

CNI Plastics, Charlotte, MI

Operations Manager 2013 to 2014

Faurecia, Taylor, MI

UAP Manager Manufacturing 2012 to 2013

Lacks Enterprises, Inc., Grand Rapids, MI 2004 to 2012

Plant Superintendent, Patterson Assembly Plant (2009-2012)

Supervisor, Patterson Assembly (2008-2009)

Supervisor, Kraft Assembly Plant (2006 – 2008)

Supervisor, Airlane NW Mold Plant (2004- 2006)

Vi-Chem, Inc., Grand Rapids, MI 2001 to 2004

Supervisor, Compounding/Extrusion Plant

Herman Miller, Inc., Spring Lake, MI 1993 to 2001

Operations Manager, Assembly Plant (2000-2001)

Supervisor, Assembly Plant (1999-2000)

Production Lead, Assembly Plant (1993-1999)

EDUCATION

General Business

Muskegon Community College

Coursework/seminars in Continuous Improvement, Lean Manufacturing, TPS, Economic Value Added, Workplace Ergonomics, Effective Business Management Program Certification, Train the Trainer Certification and Leadership Development training (Personalized Centered Approach).

Military Service

United States Army, Specialist E-4- Assignments included tours of duty in Southwest Asia(Desert Storm) and Europe during 1990-1993 as a Cavalry Scout in an Armored Cavalry Regiment. Honorably discharged.

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