Manager Manufacturing
Resume:
RAY DUDLEY
Sugar Land, TX 77479
***********@*****.***
OVERVIEW
Energetic business and manufacturing leader with experience in the lean manufacturing of plastic and metal products. Strategic minded manager that partners with sales and logistic teams to deliver high quality and cost effective production to achieve company profit targets. Strong background in multi-plant operations, budgeting, P & L management, best practice deployment, design, manufacturing and quality systems. Motivator with skill set to achieve the maximum contribution from all team members. Experienced and successful in exceeding company goals and customer expectations. ACCOMPLISHMENTS
Directed the transformation of a PVC pipe company from 5 plants in 3 separate marketing regions to 11 plants in one consolidated management system. Elevated the pipe quality to highest in the waterworks industry and increased output by 104% to the second largest in US with over one billion pounds of annual capacity.
Member of Mergers and Acquisitions Team and accountable for determining value of manufacturing assets and core competencies of personnel in target companies with positive financial results after all acquisitions.
Improved safety performance of group by 80% and achieved top quartile results in OSHA Recordable Incident Rate while doubling production capacity.
Managed and improved perception of the company to one preferred to work in by associates and with by vendors; a multi-plant operation in a public company with annual division turnover of $471M and 497 associates.
Reduced operating costs by $4.65M in eight years of accumulated annual reductions by using Lean Project Initiatives with results validated by corporate accounting.
Completed site selection, design, construction, equipment procurement and startup of two state-of-the-art PVC pipe plants that were commissioned within budgets of $17 and $42 million.
Partnered with sales and customer service stakeholders to provide the right products at the desired time while keeping manufacturing costs minimized. Successful sales and customer interface has been a hallmark of career. INNOVATIONS and COMPETENCIES
Envisioned, designed and managed the implementation of customized shop floor and inventory control system integrated into SAP Enterprise Resource Planning system with resulting inventory cycle count accuracy of 99%.
Structured and implemented bill of material and routing databases for ERP systems in discrete make-to-order, product line assembly configure-to-order and continuous extrusion in repetitive processes.
Managed capital projects from conception thru post implementation audit ranging from few thousand and short duration to multi million and two year project plans.
Trained and certified Lean Six Sigma Champion and Green Belt by Breakthrough Management Group. Motivated and encouraged stakeholders in each plant to adopt the Lean culture and complete Green and Black Belt training. Supported Quality Manager to level of Master Black Belt and brought training in-house.
Designed and analyzed new products and developed manufacturing processes using Lean methodology. Concurrent design and manufacturing engineering has been a consistent initiative throughout career.
Experienced with deep understanding of the issues involved with the startup, shutdown and turnaround of manufacturing operations. Track record of success with all three business changes.
Commissioned startup of green field polymer concrete plant in the manufacture of corrosion resistant pipe and sewer structures which included building design and equipment automation.
Commissioned the production of Linear Low Density Polyethylene, LLDPE, rotational molding of water meter boxes which were rated for traffic loading, H20.
Designed and implemented cellular manufacturing in metals machining which reduced manpower requirements, minimized material movement time, maximized throughput and improved scheduling flexibility.
Developed plastic extrusion, rotational molding, welding and machining processes to peak performance. Ray Dudley – Page 2
PROFESSIONAL EXPERIENCE
UNDERGROUND SOLUTIONS, Houston, Texas Jan 2015 – Oct 2017 Senior Process Engineer
Responsible for the design and application of Fusible PVC® pipe in horizontal directional drilling, pipe bursting and slip lining in the water, wastewater and electrical markets. Represented company during construction and field troubleshooting events on job sites. Developed contract documentation and process controls to insure pipe quality from extrusion supply chain. Mentored associates in transition to public company requirements after Aegion (NASDAQ: AEGN) acquisition. Accepted job with the understanding that VP Engineering position would be offered after retirement of current stakeholder, but retirement was cancelled due to passing of spouse and this position was eliminated.
Hands on process development in the extrusion and heat fusion of patented PVC pipe.
Designed applications and completed Technical Risk Reviews of Fusible PVC® applications across the central and western US and provided technical support to sales, customer’s engineers, general contractors and drillers.
Developed manufacturing process and quality assurance of third party manufacturing in US and India. NORTH AMERICAN PIPE CORPORATION, Houston, Texas Feb 2004 – Dec 2014 Director of Process Innovation and Engineering 9/13 – 12/14 Established a new department and responsible for manufacturing process excellence. Led the engineering and manufacturing teams in process design and optimization of all existing and new products. Developed equipment specifications, project capital budgets and purchase order deliverables for all major projects and managed implementation to insure effective execution and realization of benefits.
Aligned needs and resources using job descriptions, headcount justifications and recruiting of top talent for engineering team.
Commissioned specialty product production in three existing plants with 30% improvement in profit margin.
Member of new product design team and responsible for manufacturing process design in Stage Gate System.
Managed 40 process improvement projects and four engineers with implementations in four time zones. Director of Manufacturing 2/04 – 9/13
Responsible for all manufacturing of PVC pipe and custom products including site selection, facility and process design, procurement, operations, quality, continuous improvement, maintenance, and shipping. Accountable for Key Performance Indicators and reported to General Manager in the Vinyls Division of Westlake Corporation (NYSE: WLK). Member of mergers and acquisitions team with regular evaluation of potential targets.
Started in a new position for the company and managed the transition from three regional operations to one consolidated operation with five plants. Within six months, expanded operation with acquisition of three additional plants. Constructed two state-of-the-art plants, and acquired three additional in two transactions. Due to market conditions, shut down three of the older plants. Total operations grew to 11 plants.
Expanded capacity by 104% from 514 to 1,050 million pounds per year.
Partnered with information systems group and developed real-time system, which was integrated with SAP to manage quality, production, scrap, downtime, recycling, inventory and shipping which included bar coding and hand held computers. Virtually eliminated product shipping errors, integrated quality, drove accountability down to operator level, allowed real-time visibility in production operations and improved finished goods inventory accuracy to 99%.
Improved safety performance of group by 80% from 7.52 in 2003 to 1.54 in 2012 and achieved top quartile results in OSHA Recordable Incident Rate. Developed comprehensive safety system including standard operating procedures, job safety analysis, behavior based initiatives with peer-to-peer task safety observations, rigorous lock out\tag out culture, incident investigation with Apollo root cause analysis and incentive reward system.
Integrated Lean Six Sigma methodology into operation including statistical process control on extrusion lines, Champion, Black and Green Belt professionals, and project system which had documented savings of $4.65M with annual goal of $700k. Earned certification in Champion and Green Belt.
Developed an ISO 9002 compliant quality system and improved market image to top tier pipe manufacturer.
Developed and maintained teamwork throughout the manufacturing operation with cross training within and between plants.
PROFESSIONAL EXPERIENCE: (Continued) Ray Dudley – Page 3 LAMSON & SESSIONS, High Springs, Florida Feb 2003 – Dec 2003 Plant Manager
Responsible for turnaround and all operational activities in PVC conduit extrusion and fittings fabrication plant with 130 associates, ten extrusion lines, ten fabrication work centers and part of a public company with turnover of $316M.
Within two months, site was generating positive spending variance, which had not been achieved for years.
Improved financial performance from long running negative to $30K profit per month and sustained gains.
Reversed negative material variances to positive $50K per month and improved SAP routing and BOM accuracy. UNITED POLYMER TECHNOLOGY, Houston, Texas Dec 2001 – Jan 2003 Director of Operations
Managed the equipment design, construction and startup of green field polymer concrete products plant. Entrepreneurial endeavor which required automation of mixing process, facility and support systems design, development of safety procedures and manpower requirements.
Applied for and received air permit from Texas Natural Resource Conservation Committee, TNRCC, due to polyester resin and hazardous air pollutant, styrene.
Managed equipment and support construction in a new concrete tilt wall building thru prototype production. UPONOR ETI COMPANY, Conroe, Texas June 1992 – Nov 2001 Site Manager
Responsible for all manufacturing on property including extrusion operation which produced PVC pipe for Uponor ETI and blending operation which produced rigid PVC compounds for OxyChem under an operations contract. Shutdown and transferred blending production to new OxyChem plant and started up LLDPE rotational molding.
Accepted responsibility and full duties of two previously concurrent plant managers including 115 associates.
Managed PVC pipe manufacturing plant including production, quality, safety, human resources, purchasing, logistics, maintenance, and process improvements in a 24/7 extrusion plant with output of 54 million pounds/year.
Managed PVC blending/compounding operation for OxyChem and closure of the plant after spin-off of division. Production was 125 million pounds per year from 4 blending mixers and 3 pelletizing extruders.
Commissioned large diameter profile wall pipe extrusion line and molecular oriented pressure pipe production.
Managed the design, startup and operation of linear low density polyethylene rotational molding operation including design of automatic control system with programmable logic controllers. AMERICAN INTERNATIONAL MANUFACTURING CORPORATION, Fort Worth, TX Aug 1982 – May 1992 Major manufacturer of oil well pumping equipment with artificial lift machines sold and serviced across the globe. Director - Technical Services 7/91-5/92
Manager – Machine Division 7/90-7/91
Manager – Manufacturing Engineering 2/89-7/90
Manager – Quality Control and Manufacturing Engineering 11/87-2/89 Product Design Engineer 8/82-11/87
EDUCATION
Bachelor of Science Degree in Mechanical Engineering, 1982 University of Texas at Arlington
ASSOCIATIONS
Member of the American Water Works Association (AWWA) Member of the North American Society for Trenchless Technology (NASTT) Member of Society of Plastics Engineers (SPE)
Previous member of American Society of Mechanical Engineers (ASME) PERSONAL
Married for 36 years, two adult children with established careers, enjoy nature, travel and scuba diving
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