Executive VP / General Manager

PAUL PEREIRA

Cell # 205-***-**** ************@*****.***

CAREER SUMMARY

Proven leader with over twenty-five years of experience in a variety of advancing management and technical roles in the manufacturing, mining, automation, and power industries. Positions have included engineering, new business startup and ownership, and operations management with full P&L responsibility. Continuously recognized for strong strategic and tactical project management and employee leadership skills, and for excellent performance against corporate objectives and maximizing ROI. Advanced degree in applied behavior science focusing on leadership, employee development, accountability, team building, and cultural transformation. Adept at vetting talent and maximizing performance of individuals and teams.

PROFESSIONAL EXPERIENCE

Bingham &Taylor – Executive Vice President & General Manager 2015 – 2018

Full P&L accountability and responsibility for all aspects of a cast iron foundry plant and a plastic injection molding plant producing iron and plastic components for the water and gas industry.

Achieved 15% sales growth over two-year period through the implementation of inside sales team, increase in outside sales force, utilization of sales reps, and membership in buyer’s groups

Reduced Customer Service Issues by 40% over two-year period, increased delivery performance by 12%, and reduced lead time to ship orders by 5%

Executed green field startup of plastic injection business

Reduced injury rate by 42% over two-year period and achieved compliance with new OSHA silica regulations

Implemented real-time OEE system and achieved 13% improvement in casting productivity

Implemented new ERP system to include metric dashboards improving accountability

US Pipe & Foundry - Senior Manager, Alabama Works 2009 – 2015

Responsible for all aspects of two ductile iron foundry facilities producing ductile iron pipe for water distribution.

Full accountability for two multiple shift plants totaling 500 employees

Recordable injury rate was cut in half over 3-year period.

Achieved a 40% increase in capacity at new Mini-Mill plant over a 3-month period while increasing number of sku’s from 16 to over 160.

Implemented real-time OEE systems, leader standard work, visual factory systems, and daily management system resulting in a 25% increase in equipment uptime and 15% improvement in pipe per hour production rate.

Sponsored and initiated several Kaizen events to implement 5S, SMED, Visual Management, and Inventory Control. These systems were sustained through standard work procedures and transformed a reactive culture to a lean culture.

Initiated a reliability excellence improvement process incorporating a newly implemented CMMS (Computer Maintenance Mgt. System) as well as Total Productive Maintenance methodologies.

ALCOA INC. - Electrode Plant Manager 2007 – 2009

Electrode plant manager responsible for 24/7 production of anode assemblies used in the aluminum smelting process.

Managed successful plant turn around by improving equipment uptime providing the build of critical safety stock inventories and the capacity to execute a $16MM capital restoration process.

Achieved a 20% reduction in fuel consumption and a 7% scrap rate reduction through the implementation of standardized work and Kaizen events.

Cultivated and championed a continuous improvement team environment throughout the entire union labor workforce (98 employees) in 3 separate areas of the Electrode plant.

ALCOA INC. - Power and Mines Manager 2005 – 2007

Operations manager for three 120 MW power plants and two lignite coal mines. Responsible for electric generation requirements to run mine, smelting operation, auxiliary departments, and power sales into Texas power grid. Also responsible for final reclamation of disturbed mined lands.

Managed the successfully closure of Sandow Mine and simultaneous development and start up of $110MM Three Oaks Mine. Project included construction of the largest single flight conveyor in the world.

Managed production of power at benchmark low cost levels while running power plants in harvest mode prior to final plant closure.

Managed production and delivery of lignite coal consistently at or below unit cost targets.

Successfully renegotiated two union labor contracts to include effects bargaining for plant closure.

ALCOA INC. - Casthouse Manager 2002 – 2005

Casthouse plant manager responsible for casting 50 million pounds of molten aluminum per month into various pig and sheet products.

Improved customer delivery performance from 75% to 98% while reducing inventory by 20%.

Transformed the production methodology from a 50-year-old push system to a pull system resulting in a 10% increase in premium product capture.

Managed construction and startup of new foundry casting facility and successfully qualified product that reduced corporate shipping costs by sourcing from Texas versus Canada.

Led the team that developed a computer pairing system for metal purity that maximized high premium aluminum production and capture.

Achieved benchmark productivity and unit cost compared to similar casting facilities within the division through Lean initiatives.

DROSSTEC INC. - Operations Manager 2001 – 2002

Operations Manager responsible for the design, installation, and startup of a new secondary aluminum processing plant.

Achieved a 5% increase in secondary aluminum recovery over historical performance while reducing energy requirements by 20%.

Achieved milestone of zero injuries during construction, startup and production over a two-year period.

Developed and implemented all standard operating procedures to include environmental and safety policies.

Implemented 5S controls that allowed the customer to recycle greater than 95% of recovered metal back into casting process.

DIGITECH SYSTEMS, LLC - President and Owner 1996 – 2001

Co-owned and managed a private company providing lean manufacturing and process automation solutions for a wide variety of industries. Responsible for sales and marketing, project management, human resources, financial planning, systems design and testing, and post implementation support.

Digitech successfully designed and implemented several automation and control systems and then provided ongoing 24-hour support and maintenance services for same.

Implemented a control system that reduced power plant NOX emissions by 30%.

Implemented a power plant switchyard SCADA system that eliminated a costly equipment replacement solution and several days of downtime.

Provided 24/7 support as well as new electric and water utility installations for City of Georgetown Utility SCADA system.

ALCOA INC. - Metallurgical Engineer / Area Manager 1988 – 1998

Supervised smelting and casting departments in the largest Aluminum smelter in the US. Accountable for metallurgical practices, production, safety, training, and labor relations in departments ranging from 80 to 400 employees.

Led the team that designed and implemented a computer shop floor system that was recognized as the lean manufacturing system benchmark within domestic ALCOA facilities.

Designed and implemented a Performance Management System in a 400 employee division that resulted in an 80% improvement in production standard practice adherence.

Initiated a one-on-one subordinate mentoring program that led to improved work performance and employee satisfaction as measured by direct feedback surveys.

Reduced by 50%, the number of third step union arbitration hearings as a result of incorporating conflict resolution techniques/skills at the second step grievance level.

EDUCATION

MA, Applied Behavioral Science, LIOS/Bastyr University

BS, Metallurgical Engineering, University of Texas at El Paso

CONTINUING PROFESSIONAL DEVELOPMENT

One-on-one leadership development coaching with Innovative Developmental Techniques, Ltd.

Formal training in Toyota Production System

Formal training in Root Cause analysis

Over 100 hours of Leadership Training in a corporate setting with Leadership Institute of Seattle

Over 100 hours of Quality Systems Training

280 hours of Industrial Statistics (SPC) Courses

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