Manager Plant

John (Jack) Polk

Cartersville, GA ***** Cell: 678-***-**** ********@*****.***

Plant Manager / Operations Director

General Manufacturing / Plastics

Builds teams that work toward shared objectives in high volume or job shop manufacturing environments. Visionary leader who leads organizations towards manufacturing excellence. A strong process-oriented approach and with proven diligence in deploying the required resources to achieve productivity improvements through leadership. Lean manufacturing professional with over 20 years TPM Implementation and leadership experience. Employs an organized approach in creating simple, cost effective and resilient systems that stand the test of time. Detail-oriented and highly organized in authoring procedures, establishing flows and tracking methods. Equally comfortable participating in executive board meeting discussing strategies and performing on the front line applying the strategies.

Core Qualifications

Leadership

TPM Implementation

Analytical Approach

Budgeting / Cost Controls

Continuous Process Improvement

Start-Up Operations

Production Planning

Team Building / Staff Leadership

Cultivates Innovation

Multi-Shift Management

ISO/cGMP/AIB Experienced

High Speed/Volume manufacturing

Supply Chain Management

Customer Focus

Six Sigma Implementation

People Skills

Safety / OSHA Standards

Talent Development

Labeling and Packaging

Multiple Departmental Oversight

Technical Experience

Developed $10 million capital operating budget for plant start-up facility; led cross-functional team in site selection, plant design and build, process development, manufacturing systems design and build, quality control programs, logistics operations, product design, and plant start-up to sustain a new $45 million contract.

Expanded production facility from 19 lines to over 30 production lines including three separate processes and clean room operations.

Installed multiple lines and processes from the ground up including equipment specification and purchasing, process development and packaging automation.

Process Development

Lead New Product Development for near site customer.

Developed a Process Optimization procedure as part of a Continuous Improvement Process Control project.

Automated labeling for stamped product.

Improved facility infrastructure reliability through autonomous maintenance.

Worked through new product development including mold design and build numerous new molds.

Developed setup reduction program for multiple plant application to include repeatability and reproducibility.

Standardized mold repair, troubleshooting and maintenance program.

Reduced scrap in blow molding operations through process stabilization, setup repeatability and reproducibility, and tooling maintenance – brought a Scientific Molding approach to daily activities.

Team Building Experience

Served as Cross Functional Team and Steering Committee member developing continuous improvement programs and implementing associated ISO/OSHA standards.

Lead plant conversion from a 5 day to a 24/7 manufacturing operation to meet $40 million sales goal.

Lead efforts to change culture of work force from family-directed to self-directed leadership.

Initiated program to improve work force reliability and dependability’ across all manufacturing and warehousing functions.

Standardized hourly performance reviews across plant departments.

Total Productive Manufacturing implementation team member, Autonomous Maintenance pillar leader, Steering Team member.

Grew plant staff from 78 to 178 within 2 years, increasing sales from $17 million to $37 million.

Developed initial hire manning for 24/7 startup operation on budget.

Professional Experience

JRP Enterprise Services 1/2015 - Present

Consultant – A small business consultancy service company providing expertise from infrastructure support and training programs to supply chain management, materials management and operations management.

Spectra Metals Sales, Atlanta, GA 1/2014 – 12/2014

A U.S. supplier of metal rain control products and coated metal products. Distributions centers throughout the United States and manufacturing plants in the Southeast. A Privately owned company with $120MM in annual Sales.

Plant Manager

Key Achievements:

Developed Management team to incorporate Lean Manufacturing principles including schedule attainment and execution.

Resilux Americas, Pendergrass, GA 7/2011 – 12/2013

A U.S. supplier of plastic containers for liquid fabric care products, dish care products and hard-surface cleaners; A U.S. supplier of plastic preforms for reheat and blow applications. Resilux Americas is part of the Resilux NV company.

Plant Manager

Key Achievements:

Reduced quality credits by over $200,000 through the year 2013.

Improved the blow molding department operation equipment efficiencies improving EBITDA by $50,000.

Reduced payroll expenditures weekly by $2,000.00 without reducing headcount.

Restructured intra-plant shipping which reduced costs by $10,000 monthly.

Grew production capability to man a 4 shift 24/7 operation.

Graham Packaging, Cartersville, GA 2/2007 – 7/2011

A leading U.S. supplier of plastic containers for hot-fill juice and juice drinks, sports drinks, drinkable yogurt and smoothies, nutritional supplements, wide-mouth food, dressings, condiments and beers; the leading global supplier of plastic containers for yogurt drinks; a leading supplier of plastic containers for liquid fabric care products, dish care products and hard-surface cleaners; and the leading supplier in the U.S., Canada and Brazil of one-quart/liter plastic motor oil containers. Graham Packaging is a publicly held company (NYSE:GRM) with 7,500 employees worldwide.

Blow Molding Production Manager

Key Achievements:

Year over year improvements to bottom line through energy savings and departmental labor savings to reach 5% improvement of targeted EBITDA in a high speed/high volume production environment.

2009 Plant of the Year measured in safety, quality, and profitability.

Standardized hourly performance reviews for 100+ employees across plant departments

Introduced post mold labeling and other packaging functions.

Additional Experience

Alcan Packaging, Operations Manager (IBM, EBM, SBM, Tooling) 11/1999 - 1/2007

Owens-Brockway, On Site Leader (SBM, IBM, EBM, Project Management) 4/1995 - 11/1999

United States Navy, Norfolk, VA 5/1983 – 4/1995

Lieutenant Commander – Weapons Officer

Education

Bachelor of Science in Mathematics (BS)

United States Naval Academy, Annapolis, MD

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