Manufacturing - Food Processing Manager

Dale R. Sands Baltimore, Maryland *****

443-***-**** ***********@*****.***

BUSINESS MANAGEMENT – FOOD PROCESSING - MANUFACTURING - DISTRIBUTION

INDUSTRIAL ENGINEERING - OSHA/REGULATORY COMPLIANCE

Offer over 20 years of experience in a series of increasingly responsible positions in business management, food processing, distribution, and manufacturing operations with high volume and high dollar consumer products. Have a strong background in the design and development of state-of-the-art manufacturing and warehousing operations.

Computer literate in J.D. Edwards, AS400, and Microsoft Office Suite.

Industrial Engineering skills include process standardization, production operational layout, time study, and lean manufacturing.

SIGNIFICANT ACCOMPLISHMENTS:

Consistently selected to assess low performing business, food processing, production or warehousing operations and to restructure their internal processes to facilitate significant increases in productivity with concurrent decreases in operational and labor expenses.

Possess food processing experience (margarine and mayonnaise).

Well documented success with implementing process improvements, set up reduction programs and lean manufacturing techniques over a diverse group of industries and technical fields.

Managed in both union and non-union environments while improving employee morale.

Managed a massive plant consolidation project that involved transferring and integrating the capital

equipment from several other plants into the Owings Mills (MD) manufacturing complex. The project generated $5.5M in savings.

Developed and managed multiple automation projects that generated over $10M in savings.

PROFESSIONAL EXPERIENCE

INDEPENDENT CONSULTANT

(5/2017 to 6/2017) – Managed the lean manufacturing activities for a government contractor.

Restructured the warehouse to improve the storage and flow of inbound and outbound shipments.

Initiated a new training program supported with video documentation for unskilled employees.

Resolved several major OSHA and regulatory concerns.

Developed concepts for the restructuring of the production floor to improve work flow.

CROWN, CORK & SEAL USA, INC.

Plant Manager – (10/2010 to 4/2017) – Managed a manufacturing plant that provided specialty metal packaging to the food, liquor, tobacco and toy industries. This operation also included a food co-packing process.

Restructured the work force and manufacturing processes to provide an environment that incorporated lean manufacturing and automation.

Developed an empowered work force through succession planning and training programs.

Consistently exceeded financial budgeted targets by $350K annually.

Held dual responsibilities of Plant Manager and Plant Engineer for over 2 years.

Managed a food co-packing operation.

Developed and managed cost savings projects that provided cost reductions of $2.5M.

Provided the production and distribution support for increased sales from $17.5M to $22.1M.

ALCORE INC.

Lean Manufacturing Manager - (10/2009 to 10/2010) - Managed all lean manufacturing activities for an aerospace parts manufacturer.

Completed the restructuring of all the manufacturing work cells based on manufacturing processes rather than product line. Redistributed the work force and capital equipment to support the new work flow design.

Reduced staffing by 10% while increasing output levels by 15%.

Implemented new shop floor controls to monitor production flow.

Developed a skill assessment tier for hourly employees that supported a multi-skilled work force.

Implemented formal preventive maintenance programs to increase machine reliability and to improve quality levels.

THE A.R.T. GROUP WITH SUNRISE MEDICAL INC.

Director of Operations - (8/2006 to 10/2009) - Managed four manufacturing facilities located nationally in the custom seating and positioning medical field for wheelchairs.

Established a five-year strategic operational plan for the four manufacturing facilities.

Responsible for profit and loss responsibilities with total annual sales of $25M.

Managed two plant consolidation projects that generated $2M in savings.

Developed and implemented standard operating and quality procedures to meet FDA regulations.

Increased productivity 15% and decreased costs 10% by establishing production parameters and performance goals.

Reduced order fulfillment times 25% by restructuring raw material warehouses and improving production process flows.

Managed a vendor outsourcing project that produced over $300K in annualized savings.

Increased "on time" shipping conformance 20% by developing capacity and scheduling tools.

CAPITOL QUIKRETE (A SUBSIDIARY OF THE QUIKRETE COMPANIES)

Plant Manager - (1/2005 to 8/2006) - Managed a manufacturing processing facility, distribution functions, and a regional sales work force in two distinct market segments.

Managed profit and loss responsibilities for a facility with annual sales of $14M. Created a financial turnaround of $1.3M in net earnings.

Updated the facility's environmental regulatory plans. This included the first response training for the appropriate personnel, controlling hazmat materials, the installation of spill containment materials, and implementation of the required auditing functions.

Prepared the facility's annual air permit with the Maryland Department of the Environment.

Completed a massive housekeeping and facility upgrade program.

Implemented a finished product rotation and storage program incorporating FIFO principles.

SOLO CUP INC.-SWEETHEART CUP COMPANY, INC. (SWEETHEART CUP COMPANY INC. MERGED INTO SOLO CUP INC. IN 3/2004)

Distribution Manager - (5/2003 to 9/2004) - Managed a highly computerized and automated warehouse environment of 1 million square feet.

Completed the preparatory work for a formal capital automation project presentation involving fully automated trailer unloading. The project generated savings in excess of $300,000.

Revised the training program for the hourly work force and established new guidelines for forklift operator certification as required by OSHA.

Decreased overages and shortages of deliveries by 3.5% by establishing new criteria for hiring temporary and regular hourly employees.

Developed regression models to forecast labor requirements to meet daily shipping and receiving levels. Overtime costs were reduced by 20% while improving employee morale.

Plant Manager- (12/2000 to 5/2003) - Managed a large multi-shift manufacturing plant dedicated to many manufacturing processes.

Managed a massive plant consolidation project that involved transferring and integrating the capital equipment from several other plants. The project generated $5.5M in savings.

Prepared and managed annual budgets against standards, that included:

$39M in labor expenses and $50M in raw materials

$14.6M in variable overhead expenses (supplies, utilities, intra-co. freight, etc.)

$24.8M in fixed overhead (maintenance & repairs, depreciation, taxes, insurance)

Developed and managed four large automation projects that generated $3M in savings.

Reduced the plant's paper spoilage levels by $2M.

Developed a mass customization atmosphere with set up reduction programs, automation, and JIT principles. Reduced downtime by 25%.

PRIOR EXPERIENCE – FOOD PROCESSING (MARGARINE AND MAYONNAISE).

EDUCATION

M.B.A. in Business, (Honors Graduate) – University of Baltimore (MD)

B.S. degree in Biology, (Highest Honors Graduate) - Waynesburg College (PA)

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