Manager Manufacturing

MBA Finance Fred Ferris BS Mechanical Engineering

Naperville, Il 60565 630-***-**** *********@*******.***

Experienced Manufacturing Plant Director with a background in Mechanical Engineering supplemented by strong Financial Analytical Skills. Team Builder who leads by example with solid long term Strategic Vision. A Manufacturing Efficiency Specialist who utilizes Lean Manufacturing techniques to drive Results. Project Management skills include managing a Start-up Manufacturing Operation. Has a demonstrated track record of achieving objectives and exceeding commitments.

Strong change management skills and demonstrated experience changing a culture to a Lean environment.

Implements Value Stream Mapping and Lean Manufacturing principles to maximize manufacturing efficiency.

Experience in being the lead change agent leading complex transformational activities.

Uses ORACLE / Primavera-P6; JD-Edwards; SAP; manufacturing control system software for processing sales and work orders, inventory control and work routings.

Designs and implements continuous improvements towards production and safety.

Professional Experience

Hexion corporation, Bedford Park, IL

2015-Present

Site Leader

Oversee and manage all activities related to Production, Engineering, and Maintenance, along with full P&L responsibility of Resins Manufacturing facility. Continuously reviews financial, safety, productivity, quality, and other key performance indicators to determine areas that require improvement. Global sales revenue of $125MM.

Develop business management strategies to exploit opportunities and reduce costs/improve performance, increase throughput and manufacturing yield to meet defined growth objectives.

Reduced Operating Budget by 10% year over year through increased efficiencies.

Reduced Overtime Costs by 20% first year, then 15% the following two years.

Conducted Business analysis to Eliminate Tolling Operation at Site resulting in $250K annual savings.

Drive performance and Safety programs to maintain the highest safety performance in industry for the protection of our employees as well as sharing of EHS incidents Globally.

Implemented Lean Manufacturing /Manufacturing Excellence at the Site and quickly became the Global Standard for the company.

Proposed and Implemented Bar Coding and Warehouse Management systems reducing paperwork and process order steps by 80%. Increased product availability to ship by 50%.

Work and encourage Self-Directed Work Teams toward efficient decision making and increased production. Recognize and Develop individuals in all areas.

Managed team through Responsible Care and Sustainability Certification to UL 880 standard.

Forecast and prepared annual Capital and Expense budgets for Plant. Delivered results under budget.

Participate in Global Business and Manufacturing planning with other Divisional Sites to better utilize assets for production, improving supply chain efficiencies.

Enthone corporation, Bridgeview, IL

2014-2015

Plant Manager

Oversee and direct all activities related to Production, Maintenance, QC Laboratory, and Logistics, along with full P&L responsibility of Specialty Chemical Manufacturing facility. Continuously reviews financial, safety, productivity, quality, and other performance data to ensure goals are achieved and to determine areas that require improvement. Global sales revenue of $40MM. Reports to Corporate office in Connecticut.

Implemented plant re-organization resulting in 15% increase in throughput along with a 10% reduction in labor costs.

Managed team through ISO 14001, 18001, and 9001 recertification audits.

Dailey use of JD-Edwards ERP system and LOTUS notes for operational systems to ensure daily shipping goals are met for plant and distribution centers nationwide.

Fred Ferris

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Forecast and prepared annual Capital and Expense budgets for Plant. Delivered results under budget.

Managed projects for optimizing Batch sizes, Plant Layout Redesign, Work Cell Manufacturing, Visual Management System, and 5S.

On-boarded 4 key additions to staff including Chemist and Process Engineer.

Powell Industries--Delta Unibus Corporation, Northlake, IL

2006-2014

Director of Manufacturing Operations

Supervise 115 employees in the fabrication of Electrical Equipment for the Power Generating Industry. Responsible for the Planning, Forecasting, and daily production of the manufacturing plant.

Implemented Lean Manufacturing principles to operation, increasing rates of production and reducing labor costs. Directed the implementation of Lean Manufacturing activities in the Division. Managed projects for Batch Size Reduction, Plant Layout Redesign, Work Cell Manufacturing, Visual Management System, and 5S.

Increased production efficiencies through scheduling of workloads and products to manufacture. Introduced One Piece Flow to all 3 Focused Factories. Eliminated batch processing and set takt times and daily manufacturing schedules to achieve production and revenue goals.

Increased manufacturing output by 100%. Decreased direct labor costs from 16% of sales to 10% of sales. Reduced overtime spending by 50% for annual plant savings of over $500k.

Chaired three executive groups to drive down costs in all areas of the business resulting in 15% costs savings.

Designs and Recommends new machinery increasing production efficiencies by 50% in sheet metal / 15% in welding production work cell.

Custom Filter Corporation, Aurora, IL

2003-2006

Production/Maintenance Manager

Supervised 35 employees in the fabrication of filter products. Responsible for the daily production of five departments and the maintenance department for the manufacturing plant.

Implemented Lean Manufacturing concepts to operation, increasing rates of production and reducing labor costs. Increased production output by 10%.

Increased production efficiencies through scheduling of workloads and products to manufacture. Reduced labor costs by 7% across five departments while meeting all scheduled ship dates.

Reorganized and established responsibilities for lead operators, implemented lockout-tagout and preventative maintenance programs, developed workmanship standards for production lines, defined and monitored departmental goals.

Self Employed, Greater Chicago Area, IL 2000-2003

Owner /Manager of 3 Retail Stores

Responsible for all business operations and management of multi-site retail stores.

Increased sales 20% the first year while decreasing operational expenses by 25%.

Candle Corporation of America, Batavia, IL

1996-2000

Plant Engineering Manager

Engineering Manager responsible for staff of project engineer, process engineer and engineering technician. Responsible for the design and construction of plant modifications, repairs and new projects. Also managed state of the art controls and instrumentation for plant utilities and process.

Charged with installing a new candle press machine into a plant-wide process control system. Reprogrammed the PLC, increased the press output by 33%, and successfully completed the project two weeks before the deadline.

Formulated and managed Y2K preparations plan for the manufacturing plant. Succeeded with 100% compliance without interrupting manufacturing.

Initiated the design, and managed the installation and modifications for an in-line heat exchanger. Accomplished the goal of delivering wax to the plant batch tanks at 165 degrees consistently, increasing molding table cycle time efficiency.

Fred Ferris

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Planned and managed the improvements to the additive room allowing easy access to the tank pump manifold systems. Reduced downtime due to maintenance.

Safety Kleen Corporation, Elgin, IL

1994-1996

Project Manager – Central Division

Responsible for the design and construction projects with budgets between $75,000 and $2.5 million.

Managed projects at 70 multi-site locations throughout the Midwest.

Prepared capital expenditure authorization presentations including cost estimates, project descriptions and justifications.

Utilized cost benefit analyses to justify all projects including the use of return on investment, internal rate of return and net present value analyses.

GATX Terminals Corporation, Bedford Park, IL

1988-1994

Maintenance Superintendent

Responsible for the budget and oversight of the design and construction of plant modifications, repairs and new projects at the terminal.

Initiated a project to manage natural gas use at a storage facility and hedge purchases in the futures market. Reduced natural gas costs $150,000 annually.

Planned and managed a boiler upgrade project including water treatment and the daily scheduling of steam needs. Improved the efficiency of steam use by 50% and reduced natural gas cost

Education

DePaul University, Master of Business Administration

Finance

Chicago, IL

University of Illinois, Bachelor of Science

Mechanical Engineering

Champaign, IL

References provided upon the mutual establishment of interest.

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