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Plant Manager Customer Service

Katy, Texas, United States
August 13, 2018

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R. Sterne Rozolsky, LSSGB

**** ******* **** ****** ****, TX 77573


Proven Leader and Manager

Accomplished manager and dynamic hands on leader with a strong portfolio of successes reorganizing and streamlining the production, growth, and optimization of manufacturing assets.

Reputation for generating a strong team oriented environment driven towards measured improvements in manufacturing and production environments.

Extensive Lean Six Sigma and TPM Implementation experience.

Lean Six Sigma Green Belt . Operations Improvements . Transportation Management . Safety Programs . Quality Systems Implementation . SAP Business Software . Equipment Installation / Retrofit . Project Management . Financial Analysis . Organizational Development / Growth . Blow Molding . TPM

Professional Experience

Plastipak Packaging, Inc., Highlands TX 2016- Present

Plant Manager

Performed the reorganization of the local management team with the emphasis on establishing structure and standardization of daily processes and practices. Led factory recapitalization projects driving improvements in overall reliability and cost reductions.

Major Contributions:

Reduced annualized turnover from an initial 42% to 16% within first year.

Implemented Behavior Based Safety program that resulted in TCIR and DART reductions of 40%

Led Kaizen event focused on changeover reduction that resulted in $350K year over year improvement in operational revenue

Developed Lean Daily Management System focused on improvements of MTBF and MTTR on production equipment by implementing employee led focused improvement teams and hour by hour machine production targets.

Advanced Piping Products, Houston TX 2014- 2016

Plant Manager

Manage day to day operations of the facility with full P&L responsibility. Lead and implement new manufacturing processes introduced to the facility.

Major Contributions:

Acquired and installed new equipment to begin production of current product offerings resulting in an overall cost reduction of 43% through automation.

Implemented Supermarket Type Inventory program reducing lead time for standard offering to next day delivery from existing standard of 8 days.

Created and introduced manufacturing quality systems and trained new employees on practice and procedure.

Schuetz Container Systems, Pasadena, TX 2013-2014

Plant Manager

Performed the restructure and reorganization of the local management team with the emphasis on establishing structure and standardization of daily processes and practices. Lead performance improvements with a strong emphasis on GMP’s, 5S, standard work practices and skills training.

Major Contributions:

Increased overall through put of goods produced by 12% while reducing direct labor costs by 5%.

Implemented set min / max levels for raw inventory resulting in a reduced space requirement within the facility and improved production planning.

Led Kaizen event that developed and implemented a standard production sequence for blow mold production that optimized lot sizing and sequence to reduce overall scrap and tooling change. This resulted in an overall efficiency improvement of 19% and scrap rate improvement of 6%.

Developed a maintenance apprentice program to grow technical talent within the facility over a three year plan.

Graham Packaging Company, Houston TX. 2009-2013

Plant Manager

Transitioned an underperforming Blow Molding facility into a leader and model within the division’s 22 manufacturing plants through implementation of lean manufacturing, 5S, strategic planning, and change management. Lead a cultural shift within the plant to successfully implement a lean culture.

Major Contributions:

Reduced annual Cost of Operations by 18% targeting materials management programs, inventory planning and crewing management through use of SQDC Metrics and Lean Daily Management.

Improved overall MOEE by 14% through the use of autonomous maintenance, standardized work, focused improvement projects, and visual controls and triggers.

Reduced annual turnover in the plant from 32% to 12% annually.

Improved the overall safety of the plant to a TCIR of .74 using associate participation in behavior based safety programs, audits, and committees.

Metals USA Building Products, Houston, TX . 2006-2009

Director of Operations

Handpicked by the CEO to streamline and improve operational efficiency of a struggling division. Driving performance goals and expectations for multiple manufacturing plants on both the East and West coasts as well as Canada. Lead performance improvement in the areas of production efficiency, cost reduction through waste elimination, and improved safety with a strong focus on customer service and profitability.

Major Contributions:

Consolidated and absorbed two manufacturing facilities (one over 500,000 SQF) and redistributed production and distribution resulting in a net reduction in operating costs of over $2.5 million dollars per month.

Improved customer service by improving delivery schedules and reducing lead times for manufacturing utilizing lean principles and improved material flows.

Reduced the number of recordable injuries 60% over prior years through improved safety programs and enhanced awareness programs.

Streamlined inventory program resulting in 40% reduction of goods over 2 years.

Metals USA Specialty Flat Rolled, Liberty, MO . 2000-2006

Director of Operations

Elevated organizational performance and total production capacity year over year resulting in the facility being the most profitable in the division. Contributed to overall management of site and business development with respect to operational and distribution requirements.

Major Contributions:

Successfully completed two major construction additions doubling the manufacturing footprint.

Using Lean Manufacturing principles, redesigned material flow through the plant resulting in significant productivity improvements and reduced handling points.

Orchestrated and implemented the installation of STELPAN computer system into two service centers.

Significantly improved overall logistics expense by incorporating backhauls into daily truck runs and improved truck routing practices.

Propelled work force to three consecutive years without a recordable injury through enhanced safety awareness programs and employee ownership.

Captured superior levels of customer satisfaction through quality, service, and support.

Metals USA Flat Rolled, Northbrook, IL . 1995-2000

Assistant Plant Manager

Instrumental in daily management and production functions of a 400,000 sqf service center optimizing production, delivery, and maintenance schedules to accomplish set goals.

Lead and motivate a strong union work force to meet continuous improvement goals and expectations.

Pioneered a new heavy gauge slitting technique eliminating chatter and camber on slit strip that did not require major machine retrofit.


The University of Tennessee, Knoxville, TN

B.S. Mechanical Engineering

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