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Plant/Operations Manager with strong LEAN background

Dayton, Ohio, United States
April 09, 2018

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Ed Ponikwia

Centerville, OH ***** 937-***-****

Experienced Plant / Operations Leader

Manufacturing Operations Continuous Improvement Lean Management

Results-oriented manufacturing and operations leader, directing efficient daily operations across multiple sites and product lines, delivering products within demanding targets and deadlines. Innovative in championing change, streamlining processes, reducing costs, and achieving operational goals. Trusted business partner, achieving impeccable safety standards and complying with strict regulations. Natural leader, mentoring and managing cross-functional teams, troubleshooting and resolving complex production issues with minimal downtimes and risk, achieving year-over-year results.

Manufacturing & Production Management Capacity Planning Lean Manufacturing

5S ISO9000 Kaizen Six Sigma Champion Budgeting Risk Management

Continuous Improvement Warehousing & Stockrooms

Professional Experience


Production Manager 2016 – 2017

Managed team of approx. 20 in product assembly of high end outdoor gas fire pits

Set record company shipment results for 11 consecutive months, Delivered results within all key metrics of site, driving productivity, safety, on time delivery, EHS and more.

Established and tracked metrics to drive improvement in safety, on time delivery, quality.

Implemented LEAN & 5-S processes and cost reduction ideas.


Manager, Factory and Packout 2015 – 2016

Provided oversight to 2 shifts of manufacturing electronic equipment assembly, such as GPS devices and related sensors for various business areas, as well as custom kit packing and configuration of products ready for distribution. Managed 70 – 100 non-union, full time and temporary resources.

Integrated 2 business acquisitions into operations in Tipp City location, working collaboratively with key stakeholders to minimize downtimes and risk and meeting demanding budget and deadlines.

Implemented Lean and Six Sigma methods across multiple processes, reducing costs 7.7% in factory and 3.5% in pack-out, and adhering to strict standards and regulations.

Increased pack-out utilization 12.4% by improving screening and training of temporary workforce and boosting communication across all business areas.

Controlled safety risk by conducting assessments, implementing department communication boards and utilizing frequent training huddle meetings.


Operations Manager 2014 – 2015

Managed team of approx. 50 in product assembly, refurbish and repair and onsite service of control valves.

Delivered results within all key metrics of site, driving productivity, safety, on time delivery, EHS and more.

Ed Ponikwia Page Two


Plant Operations Manager 2004 – 2013

Directed more than 150 personnel resources across 3 shift operation of 350K sq. ft. manufacturing site with annual sales of $160M. Managed EHS, quality, customer satisfaction, production supervision (label printing, band molding and ASSY), planning / scheduling, productivity, cost, manufacturing and industrial engineering and on time delivery.

Streamlined order picking / shipping process, saving 3X investment by using Lean methodology.

Increased on time delivery of IPS labeler products from 75% to 98% by defining improved scheduling techniques and implementing Kaizen events.

Led project to cease operations of Sayre, PA plant and integrate product lines and processes into Miamisburg, OH facility, completing project within defined objectives and deadlines.

oAchieved business goals by reducing overhead and increasing productivity.

Improved RIR for facility from 9+ to less than 1.0 by facilitating safety audits and continuous improvement activities.

Implemented digital label and tag printing into Miamisburg operations for low volume runs, reducing costs.


Plant Manager 1993 – 2004

Directed production of low volume / high mix business products such as money order dispensers, forms bursters, check encoders, gift certificate dispensers, and more. Managed production, machine shop (CNC and manual equipment), finishing operations, assembly, manufacturing and industrial engineering, planning / scheduling, procurement, engraving, EPROM center, safety, and documentation services.

Achieved longest safety record in plant history (10 years with ‘0’ lost time accidents) by building strong safety culture throughout all departments.

Increased productivity and reduced cost each year by spearheading many continuous improvement actions, including work-cells, TQM, Kanban, setup reduction, utilized extensive cross training and Six Sigma training.

Improved company position each contract by representing company on union contract negotiating team for 3 contracts with IUE-CWA and IAM unions.

Controlled expense and capital budgets for plant and plant engineering, securing cost savings and meeting financial targets.

Senior Project Engineer

Product Design Engineer

Additional Relevant Experience


Various Design and Project Engineer positions (5 Design Patents)


Bachelor of Engineering (BE), Mechanical Engineering, Youngstown State University, Youngstown, OH

Community Activities

Chairperson, Charitable Contributions Council, Standard Register Co.

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