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Manager Manufacturing

Waxhaw, North Carolina, 28173, United States
February 19, 2018

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HAL ROGERS **** Beaminster Place

Cell 704-***-**** Waxhaw, NC 28173


Executive with significant experience in Manufacturing and Healthcare. Career includes Lean Sensei, Consulting Account Manager for 19 Healthcare systems, Vice President (VP) of Engineering Services, VP of Lean Manufacturing, VP of Corporate Product Marketing, VP of Manufacturing, and Plant Management.

Competencies include:

* Global Cultural Experience

* Strategy Deployment

* Manufacturing & Healthcare

* Leadership Development

* Change Management

* Lean Transformation

* Facility Design 3P

* Total Productive Maintenance

* Project Management


CAROLINAS HEALTHCARE SYSTEM– Lean Transformation 4/2016 - present

Lean Sensei – Charlotte, NC

Worked with CMC Main SHVI OR leadership and created capacity for 50 additional surgeries a year. This resulted in an increase in gross revenue of approx. $1,500,000

Partnered with EVS to reduce discharge room cleaning by 32% from 133 mins. to 90 minutes

PERFORMANCE SOLUTIONS BY MILLIKEN – Lean Transformation 7/2015 - 2/2016

Sr. Director of Healthcare Consulting Services – Spartanburg, SC

Developed comprehensive Lean Healthcare consulting strategy with supporting services from Market Development through multiyear client engagement. This was a new sector of Consulting for PS by Milliken

SIMPLER CONSULTING (Truven Analytics) – Lean Transformation 1/2010 - 6/2015

Account Manager - 19 Healthcare systems – Charlotte, NC (9/2012 - 6/2015)

Responsible for organization wide Lean Transformation working with a team of five sensei

Consistently provided annual savings of $12 million with an ROI greater than 8

Provided regular one on one coaching to C suite leaders on Lean leadership and transformation.

Healthcare experience includes: Revenue Cycle, Emergency Services, Surgical Services, Lab, In- Patient, Urgent Care and Primary Care

Senior Consultant for Healthcare and Manufacturing clients – Charlotte, NC (1/2010 - 9/2012)

Lean Sensei for three urgent care centers, four independent hospitals and one manufacturing facility.

Implemented savings of over $4,000,000 annually

Reduced overall ED LOS by 26% from 195 mins to 145 mins

PARKER HANNIFIN 1/2009 - 12/2009

Group Manager of Lean and Quality – Cleveland, OH

Responsible for Lean and Quality for 19 divisions with 43 facilities in 15 countries

Utilized Product Profit, Volume, and Complexity analysis to identify products needing to improve profit margins

COLLINS AND AIKMAN - Tier 1 Automotive Supplier 1/1986 - 4/2008

Vice President of Engineering Services – Albemarle, NC (2005-2008) Provided Engineering support to 22 facilities in North America. Managed capital budget of $30 M.

Responsible for the Lean design and installation of equipment

Approved all equipment and facility layouts minimize cost and ensure optimum flow

Capital avoidance of $2-3 M annually and savings of $1 million of income annually

Vice President of Engineering/Lean Manufacturing - Albemarle NC (2002-2004)

Provided Engineering support for 30 facilities. Managed capital budget of $35 M.

Implemented Lean manufacturing in 30 facilities in Europe, Mexico, Canada and the United States

Refined equipment selection & implementation process to reduce time from identification of need to implementation and successful startup

Developed Organizational Strategy to create and support Division’s Lean Cultural Transformation

In 2004, we freed up 144,000 sq. ft. of floor space, and realized labor savings of $7.2 M annually

Vice President of Product Marketing - Troy MI (2001)

Liaison between Sales, Marketing, Manufacturing and Product Development

Implemented system to focus and maximize product development initiatives

Developed marketing/pricing strategies

Created comprehensive market/competitor analysis

Vice President of Manufacturing - Albemarle NC (2000)

Responsible for four facilities: 175 salaried, 2,100 total employees, sales of $370 M.

Championed implementation of lean principles and tools in four facilities

Reduced Manufacturing cost by $9M

Director of Operations – Greenville, SC (1998-1999)

Responsible for two manufacturing facilities: 125 salaried, 1,200 employees, sales of $170 M.

Turnaround of underperforming business - replaced key managers, created lean structure

Reorganized salary structure, eliminated 19 positions, saving $1.6 M annually

Redeployed 115 hourly positions using leveling and standardized work saving $3.9 M

Reduced customer returns by 80 % by involving associates, and implementing built in quality systems

Reduced inventory by 25 % by reducing changeovers, and use of Kanban

Additional Relevant Experience:

Plant Manager, Division and Plant Industrial Engineering Management


MBA, Winthrop University, Rock Hill SC

BS in Business Administration, Appalachian State University


Toyota Production System - Toyota

Toyota Supplier association member (TPS) 1998-2008 - Toyota

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