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Manager Plant

Carleton, Michigan, 48117, United States
May 17, 2018

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Brian K. Kirby

***** **** **. *** ******, MI ****4

Phone: 734-***-**** Email:


~ Six Sigma Green Belt Certified ~

Achievement focused, self-motivated and directive professional with over 20 years of hands on experience in all facets of Materials, Planning, Logistics and Plant Production field, including experience as a Supply Chain Manager. Results oriented with a proven track record of accomplishments. Inclusive but not limited to consistent cost reduction and volume increase. A proactive leader with expertise in troubleshooting, initiating change and implementing quality improvement processes through willingness to go the extra mile.


* Project Management * Production Planning & Scheduling

* Team Building & Leadership * Client Relationship Management

* Cost Reduction Management * Service Part Management/Buyer


Meritor – Livonia, Mi Dec. 2017 – Current

Site Manager(Plant Manager)

Cordinate and exexute business plan and budget for new (take over) plant

Increased customer Service rating from 48% up to 96%

Mentored team on quality standards

Implemented 5’S – Housekeeping

Managed all operation functions with managerment and supervisor teams

Cross Trained Management team

Reduced overtime up to 60%

Increased revenue in upwards of 30%

Plastic Omnium – Huron Twp., Mi Feb. 2017 - Dec. 2017

Materials Manager/Supply Chain Manager

Improved customer delivery scores from 58 in 2016 to 91 in 2017

Developed Cycle Counting Schedule for materials

Improved overall KPI’s in the plant.

363 million in sales – 9 different OEM’s

Freight savings of over 806K in 8 months.

Outsourced small builds for a savings of 216K

Hired and trained Material Planners

Implemented service check list for all outgoing service

Initiated Ford Q1 process

Anderson Cook – Clinton Twp., MI July 2016 – Feb.2017

Plant Manager / Divisional Materials Manager

Enhanced customer relations to improve customer service

Trained maintenance department to develop PM program

Initiated a Cycle Counting System for both Materials and Maintenance

Improved Delivery Rating with ZF from 6% to 100% in one month

Developed Material/Production matrix to increase efficiencies through reducing scrap, cost save on tooling and reduced labor spend.

Organized warehouse for better plant to configuation (FGI, Dunnage & 5’s)

Creatied inventory management and budget implantation for all incoming Material

Created all KPI’s for the plant for both Production and Materials Dept.

M.I.S.C. - Brownstown, MI & Louisville, KY Sept. 2008 – June 2016

Plant Manager – 2 Plants

Launched operations of a 2.7 million dollar plant

Controlled all Freight incoming and out going

Recruited, hired and trained all management employees as well as hourly

Completed, implemented and maintained budget controls

Reviewed and approved all accounts payable

Lean Implementation. Develop and drive lean and cost saving strategies throughout the plants

Set up Material Control Process

Integrated Logistics systems

Set up Inventory Management system

Load plan for incoming and outgoing Material

Johnson Controls – Plymouth, MI September 2007 – September. 2008

Sr. Supply Chain Manager

Supported 28 North American JIT plants (3 Mexico, 3 Canada and 22 Untied States)

Project Manager of a 26 Million dollar freight pack density expense reduction program

oInitiated Trim and Bundle in 28 plants (eliminating return freight)

oImplemented Foam in Bag project (eliminating return freight)

Worked with Pro E, SAP and MRP

Worked and Trained Master Scheduler for 20 plus plants

Worked and Trained Shipping and Receiving Supervisors

Assisted with inventory reductions across the entire portfolio

oWorked with 3PL on cross docking material, looked at all savings. Broke it down into groups and lowered our freight as a whole

Lear Corporation – Brownstown, MI February 2007 – September 2007

Production/Plant Manager

Managed 400 hourly UAW workers, 2 superintendents and 14 supervisors in 2 shift operation that produced over 200 million in annual sales

Produced seats for three different OEM customers (Ford, GM and AAI)

World Class Housekeeping

oManaged all aspects of in plant housekeeping to meet Lear standards

Lean Manufacturing – Continuous improvement

Lear Corporation – Brownstown, MI March 2006 – February 2007

Materials Manager

Managed inventory for JIT facility with monthly inventory levels exceeding 200 million

Monitored daily shortage reports

Conducted bi-annual physical inventory and reconciliation

Supervised 8 Materials Coordinators, 6 Shipping Supervisors and 56 Hi-Lo drivers.

Monthly MOS

Managed obsolescence claims

Conducted annual employee evaluations

Reduced inventory levels by 4.2 Million

oLowered inventory levels through training Materials Coordinators in Lean Methodology

Negotiated freight reduction resulting in over a million dollar savings

oTotal freight savings 1.6 million

Maintained BOM’s

Worked with Corporate Buyers

Ran AS400 & EDI systems

Improved after market service ratings from a 4 to a 1 on GM service

oImplemented photo process control system

oCreated Service Check Sheet requiring all service to meet certification guidelines prior to shipment

Lear Corporation – Louisville, KY January 2005 – March 2006

Materials Manager

Supported U251 launch program

Managed inventory for JIT facility with monthly inventory levels exceeding 100 million

oUtilizing AS400

Monitored daily shortages

Conducted bi-annual physical inventory and reconciliation

Supervised 5 Material Coordinators, 6 Shipping Supervisors and 16 Hi-Lo drivers

Monthly MOS

Managed obsolescence claims

Negotiated freight reduction resulting in over 250 thousand dollars in savings

Maintained BOM’s

Ran AS400 & EDI systems

Lear Corporation – Southfield, MI September 2003 – January 2005

After Market Parts Manager

Improved delivery rating from 72% to 98.7% over 12 months

Lowered RPPM’s from 1180 in 2003 to 37 in 2004 with Zero QR’s

Held monthly service meetings with 32 plants within Canada and United States

Developed and distributed service check sheet

Conducted service workshop (DDL training)

Created and implemented a photo process control system

oDigital photos of all after market parts shipped

Developed cost modules for service

oIdentified non-profit parts to allow for negotiations with OEM

Assisted with managing 6 plant closings – transferred all service parts

Lear Corporation – Romulus, MI January 2002 – September 2003

Assistant Materials Manager

Issued weekly releases to suppliers while monitoring accuracy and proper lead time

Managed inventory and distributed delivery requirements to the supply chain

Coordinated engineering changes with production team

Participated in Kaizen workshops through Mazda North America

Trim and Bundle Green Belt project

Lear Corporation – Lagny Le Sec, France June 2001 – January 2002

Project Manager/Production Manager

Supported Peugeot 206 launch

Placed as Interim Production Manager

Trained 120 hourly employees on sure bond processes

Lear Corporation – Romulus, MI September 1998 – June 2001

Material Analyst

Managed scheduling of 26 suppliers for over 900 various parts

Ran AS400 & EDI systems

Monitored daily shortage reports

Coordinated engineering changes with production team

Maintained BOM’s

Lear Corporation – Romulus, MI September 1995 – September 1998

Production Supervisor

Managed 42 hourly UAW workers

Supported 3 launch programs

Attained Compass Program knowledge

Lear Corporation – Romulus, MI January 1994 – September 1995

Shipping and Receiving Supervisor

Responsible for operations of Shipping /Receiving Department

Supervised 16 forklift drivers.

Managed all material movement, placement and maintenance

Monitor all freight documentation for all inbound and outbound shipments

Maintained First In First Out (FIFO) throughout the plant

Professional Preparation:

Lawrence Technological University

Survey of Quality Tools Certificate – 2007

Ford Motor Company

CMMS3 Ford Production Suppliers – 2007

DDL Ford Customer Service Division - 2004

Eastern Michigan University

8D Problem Solving with Team Building – 2007

Lear Corporation

Six Sigma Green Belt – 2003

Northwood University, Southgate, Michigan

1996-1998 - Current Major: Business Management.

ETA: Completion June, 2020

Member of the Allen Park School Board.

Pres. of Allen Park Football Boosters – Raised over $150,000

Pres. of Allen Park Baseball Boosters – Raised over $75,000

Curated WWP (Wounded Warriors Project) – Raised money having a Military Night

Baseball Coach -t Allen Park High School - 11 Years

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