David Metzgar

ac63qi@r.postjobfree.com M: 423-***-**** 9214 Volans Ln Harrison TN 37341

Paint Production Supervisor/Jig Process Manager

Objective

I am looking to step into the next level in my career by securing a position that offers both challenge and opportunity for my career development while at the same time serving the organization to the best of my capabilities. I would like to gain new skills while utilizing my knowledge, training and experience to serve and better the company.

PROFILE

Paint Production Supervisor with over 7+ years of diverse OEM and Tier 1 paint experience.

High attention to safety, quality and detail

Strategic thinker with the ability to quickly learn and understand new position rolls and tasks.

Proven strong leadership skills with a reputation to train, influence, motivate and lead individuals and groups of people. Experience with managing various levels of subordinates.

Work well and am able to keep a level head under high stress and time urgent situations.

Goal-oriented, organized and detail-directed problem solver

Proven ability to work in unison with authority.

Self-motivated with ability to work independently and lead others.

Experience with OEM and Tier 1 new plant and program startup and project development for VW and Plastic Omnium.

Developed production processes to improve process flow, defect detection, product traceability and best practice process standards.

AREAS OF EXPERTISE AND EXPERIENCE

Production Supervision

Lean Manufacturing

Problem Solving

Jig Process Management

Value Stream Mapping

Quality Control

Process Improvement

5S – Organization Management

Work Instruction creation and development

Process Auditing

Waste reduction

Cost Reduction and Control

Continuous Improvement

Kaizen

Training, coaching and employee development

Process Development and Design

Plastic Omnium and Volkswagen A3 (problem solving) Methodology

Paint Jig Design and Modification

Paint Robotic Programming/Application

Paint mixing systems and process

New Project Development

Production Line Balancing

ISO / TS and IATF Auditing Compliance

PROFESSIONAL EXPERIENCE

Plastic Omnium Auto Exterior –Chattanooga, TN 2015 – Present

Paint Production Supervisor – Loading Process, Clean Room, Paint Mixing Process, WINN CC (paint schedule programming)

Paint Jig Process Manager

-Areas of supervisory responsibility

Load Area – (8 team members) Process Responsibilities – Reviewing incoming injected part quality. Loading the paint line with parts per the production schedule. Inspection and cleaning of all parts loaded on the paint line.

Paint Mix and storage room – (2 team members) Paint mix room and storage processes design, setup, startup and assistance with commissioning. Operations and technician supervision. Responsible for process flow, FIFO and Paint In process management, performance, organization, work instructions, 5s and CIP. Development of PPCM check list.

Clean room – organization of processes and management of rules specific to 5s and people management

WINN CC –Key User for programing the paint production line scheduling system.

Jig Change Process – Manage all jig change operations including, mast cover changes, jig cleaning, supplier quality, jig operation employees. Design and fabrication of new product jigs and WIP rack designs. Manage 3rd party contractors/suppliers responsible for the cleaning, fabrication and repair of process equipment. Organize and schedule maintenance activities and PM’s related to the jig process equipment.

1.People Management Responsibilities

Interviewing, hiring and promoting of temp and permanent employees.

Employee pay roll and attendance – tracking of team member vacation time and use of ADP systems to track and record employee hours.

Corrective action reporting – auditing, tracking and documenting of team member performance and actions. Addressing and taking steps to correct deviations through training, coaching and corrective action.

Perform safety observations and report results to the production team and HSE manager through the Top Safety program, to improve heightened awareness of safety concerns..

Incident reporting – safety incident reporting and corrective action planning.

Performance Evaluations – monitor, audit and assess team member and technician performance and job knowledge. Perform level of performance (LOP) reviews and document performance details in the skill matrix.

Team member training – Training of team members on safety, quality, work instructions, proper procedures, and company policies to follow while performing job functions. Coaching struggling operators to the level of performance required for their assigned position.

2.Miscellaneous responsibilities and involvement

Problem Solving (A3 and Kaizen) – Group leader for problem solving and process improvement projects. Projects include – cost reduction, scrap reduction, downtime and process quality improvement and optimization.

Work Instruction creation and revisions

Level of performance (LOP) and skill matrix documentation.

HSE compliance auditing for HAZ waste and chemical handling, storage and inventory.

Process auditing – review processes performed by the technical and production staff in accordance to company and process standards. Conduct observations for improvement opportunities. Document, develop and implement the improvement opportunities.

Production Supervision System (Key User) – Setup of the production system for SAP information, new parts, process styles and paint colors. Program the paint production systems according to customer demand and logistics scheduling plan.

Quality involvement – training of the loading team on paint and injection quality defect recognition and identification

Responsible for meeting targeted KPI’s (Key Performance Indicators) Safety, Quality, Cost and Productivity

Continuous improvement (CIP) practices and training – improved process flow and cost reduction.

Cross department project management and coordination – Paint/Injection CIP and problem solving activities.

5s process – Paint clean room, mix room, storage room, load area, and jig change process creation and implementation. Audit and document deviations and opportunities to improve.

Supplier and contractor project involvement – arrange for quotes, services and work to be completed by suppliers and contractors. Range of work and experience includes organizing projects, purchasing and validating services provided.

Responsible for the purchasing process related consumables, equipment, materials and modifications.

Responsible for providing loading and jig process annual budget numbers, and adhering to the set budget, while also looking for improvements to reduce cost.

RECENT ACCOMPLISHMENTS

I have led two successful Kaizen events in 2018 resulting in cost reduction ($19K and $75K), optimization of our paint line processes, reduction in operator and equipment run time and improved efficiencies throughout the paint line process.

I have led my team in creating the new benchmark standard for Plastic Omnium production, organization and 5s standards for the paint load, jig change and clean room processes, by surpassing the company standards, targets and previous benchmark, during the annual corporate paint assessment audit.

Developed the 2017 and 2018 budget for loading and jig change consumables and operation expenses.

Created a 6 month cost savings of $90,000 through management of paint consumables and jig cleaning.

Reduced the scrap rate caused by the paint loading area from 2.35% to .12%, surpassing the division and internal targets.

I have reached and surpassed all of my individual KPI’s for 2015, 2016 and 2017.

Reduced individual team member overtime from an average of 7 hours per week to >1.05hours per week.

I have passed all audits for each of my areas of responsibility, with no derogatory remarks. Audits include (PO Paint Assessment, TS, ISO, Health, Safety, Environmental, 5s Presidential, IATF, VDA, Lackrevision)

Designed and developed all work instructions, processes documents and training plans for the paint load area, jig change process, mix room and paint storage processes.

I created the spec book for our jig cleaning suppliers and for the development of improved cleaning processes.

Reduced paint scrap caused by dirt from 6% at the beginning of the 2017 to 2.75% through means of increased monitoring and cleaning of paint jigs, improved filtering of paint, and improved air filtration in the robot booths.

I have developed a damage and defect library with visual aids for operators to identify issues and quickly determine scrap root causes

I have created a communication path between paint and injection and created an escalation plan for quickly identifying and addressing quality issues with injection, paint and quality. An information board has been created for operators to review defects and quality alerts that detail the outlined issues.

Created contingency plans for each area I supervise for man power and process assistance through means of cross training each operator and technician to learn an additional task or area.

I have created documentation that is used for monitoring each process and function to determine the strengths and weaknesses of each area. This documentation also serves the purpose for monitoring equipment reliability and functionality, deviations from standards, limitations of equipment and operators. Through the historical data from this documentation, I have determined a set of Golden Rules for operators to follow that highlight the desired expectations, limitations and requirements of the equipment and the operators.

Volkswagen Group of America (Chattanooga Operations) 2011-2015

Paint Robotic Application Lead Programmer,

Top Coat - team lead - robotic application programming

Advanced robotic programing and robotic maintenance - at Durr Bietigheim-Bissingen, Germany

Equipment operation and maintenance courses chiller units at SINGLE Temperietechnik – Hochdorf, Germany.

VW Team leader training course

Robotic application programming, optimizing and operations training

2K paint technology training

8 step problem and A3 solving – Classes and hands on training.

Team leader experience in Top Coat, E-Coat Sand, Recoat, Cavity Wax, Paint Mix Room and Sealer.

Water-borne application process

Responsible for development of new application programs along with optimizing existing programs.

Developed procedures for application startup, maintenance and shutdown.

Developed application improvement methods and standardized processes for fault recovery, application defects and quality inspection.

Organization and management of workshop for cross department problem solving.

Training including - Robotic Safety, Hazard Communication, Lockout Tag Out, Personal Protective Equipment, Fire Extinguisher, Hazardous Waste, ISO and Respirator testing

Green Field OEM paint Shop start up experience.

Other areas of responsibility

1.Document and presentation preparation and editing using Excel, Word and Power Point

2.Document retention

3.5S and Standardized work, operator auditing and document editing

4.Paint defect source investigation – Root cause analysis

5.Process setup and layout design (Perfect Pitch) methodology

6.Quality Containment auditing for corrosion and paint application defects

Peyton’s SE, Cleveland TN 2005-2011

Plant Systems Maintenance.

Maintaining, operating, controlling and troubleshooting Witron automation systems and programs - TGW automated robotic stacker cranes – automated palletizer – conveyor sorting systems – elevator controls

Production systems coordinator

Conveyor control operation, repairs and troubleshooting.

Photo and proc sensor alignment and repairs.

Pneumatic and hydraulic equipment repairs

Electric motor and control repairs

Job order reporting and creating.

First responder safety team leader.

Experience working with (mig, tig and stick)welders, lathes, cutting torches, band saws, industrial label machines, industrial sealers, compactors, lifts, elevators, conveyor systems, hand control desks (teach pendant), hydraulic press, industrial battery machines, drill press, bench grinders and hand grinders, industrial compactors…)

Robotic, electrical, preventative and general maintenance work. Hazard Communication, Lockout Tag out, Personal Protective Equipment, Fire Extinguisher, Hazard Waste, Fork lift license

EDUCATION

High School Diploma, Shenandoah Christian Academy- Graduated 2003

Criminal Justice, Pensacola Christian College- 2003-2005

Advanced Robotic Paint Application, Programming and Maintenance, Durr Systems GMBH – Beitigheim-Bissingen, Germany- 2012

Systems Control School, SINGLE Temperietechnik – Hochdorf, Germany - 2012

TRAINING AND CERTIFICATIONS

Paint Application and Team Leader Training and Certification- Volkswagen GOA – 2011

Leadership/Management Training – Upstate Employers Network -2016

Plastic Omnium 2015 to Present Training Classes - Plastic Omnium Manufacturing System (POMS), Certify and Expense Reporting, POSITIVE, Industrial Performance Indicators (IPI), Focused Improvement, Resource Conservation and Recovery Act (RCRA), Single Minute Exchange of Die (SMED), 5S methodology, Waste Elimination, Leadership Accountability-B, Product Lines - Structural parts, Leadership - Accountability-A, Supplier PPAP Online Introduction, Leadership Chattanooga- Coaching, 5S Methodology / Practice / Procedures, SAP Training Levels 1-2-3-4-5, Plastic Omnium Way for Effective Recruitment, Standard Work, SAP Basic Training and Introduction, RCRA Annual Training, Anti-Union: Engaged Workforce, TESIS Introduction, Quality Mindset, Particle Counter, Transtocker loading and unloading, Top Safety, POAE Leadership Conference, E-Time & Attendance Policy, Paint ‘in, QRQC Training, PPCM basics, Jigs: Design maintenance and Control, General Introduction to HIPAA and Privacy Regulation, My Learning Place for Managers, OPteam - Annual Assessment Review for Employees, Complete Automation Mixing Room, Surface Treatment : Flaming (Operation and Maintenance), Lockout-Tagout- Authorized, HTI Management Training, Paint RFT Golden Rules, Paint STOELR, Solving Problem Tools, DOT Hazardous Materials Transportation, RCRA_Hazardous Waste Management, Global Harmonization, HSE Orientation, Value Stream Mapping, Kaizen Training

References –

Anthony Willingham – Plastic Omnium – Paint Process Manager – 256-***-****

Mike Keglovic – Plastic Omnium – Plant Paint Engineer – 423-***-****

Enrique Ayerdi – Plastic Omnium – Paint Project Development Engineer - 423-***-****

Rodney Bunner – Plastic Omnium – Paint Unload Process Supervisor – 423-***-****

Jason Gaddy – Volkswagen (Chattanooga Plant) – Paint Shop Production Manager – 423-***-****

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