Sign in

Manager Engineer

Columbia, South Carolina, United States
December 20, 2018

Contact this candidate


Rick Byrd

Operations Leader


I have extensive management and practical work experience encompassing mechanical, hydraulic, electrical & electronic manufacturing, engineering, material planning, supply chain management, production control, warehousing and logistics, facilities and operations incorporating an enterprise-wide operations strategy. I am a results oriented, hardworking, resourceful team builder with accomplishments in:

Materials Management Enterprise-wide Strategic Planning

Production Planning and scheduling Customer and Supplier Needs Assessment and Satisfaction

Inventory and JIT Management Innovative Crisis Management and Problem Resolution

Continuous Improvement Method Deployment Supervision, Recruitment and Team Building

Adapting ISO and TS standards ERP System Development

Policy Deployment Continuous Improvement Champion

Sales, Inventory, and Operations Planning (SIOP) Recruit Assess Select & Mentor Talent to Maximize Impact

Annual Plan Budget Development and Oversight Flexible and Thrive in fast-paced environments

Strong interpersonal skills at all Enterprise levels Expert at Re-introducing and Reinvigorating Lean Culture


Harsco Rail Feb 2008 – Dec 2018

Harsco Rail is a global manufacturer of railroad maintenance of way equipment and division of Harsco Corporation with sales in excess of $3B annually. Specialization is complex engineered-to-order or make-to-order high complexity equipment with little forecast visibility.

Site Manager / General Manager

Promoted rapidly through the organization and have held several positions including Manufacturing Engineer, Manufacturing Engineering Supervisor, Engineering and Facilities Manager, Production Manager, and Site Manager responsible for general management direction of all operations functions

Increased on time delivery of equipment from 35% to 100% over 3 years by implementing SIOP and lean / continuous improvement / lean process throughout the organization. This, along with better inventory planning, also reduced lead times of standard products from 6 months to 6 weeks. Standardizing the line layout, build techniques, and separating configure to order options further reduced the lead time from 6 weeks to 2 weeks

Increased on time delivery of aftermarket from 72% to 96% over 2 years by studying market trends and implementing a robust ABC/XYZ inventory planning system to maximize ROI of holding inventory

Increased employee satisfaction rating from 62% to 76% in 1 year by implementing employee led teams focused on improving communication, inclusivity, and employee engagement in all aspects of the business.

Accomplished 10% plant productivity gains for the past 3 years

Achieved over $800k in positive margin contribution in 2018 through visual scheduling, better inventory planning and daily accountability

Managed plant re-layout project to remove waste and optimize manufacturing processes. Project took over 18 months and $4.7M in capital and led to a documented $18M in realized savings

Using design for manufacturing techniques, worked with Product Engineering to launch MOR 96-Stone Grinder project. This resulted in the most efficient and profitable project of its kind in company history

Developed supply and manufacturing strategy for Engineer-to-Order and Make-to-Order products reducing lead time and cost

Consolidated two production lines from another manufacturing plant into Columbia, SC operations with minimal customer impact

Routinely budgeted and managed capital projects of $3-5M annually

Developed and implemented skill-based pay program giving hourly employees a path to earn more money while becoming more valuable to the organization by gaining skills and flexibility

Reduced accidents and lost-time injuries from 8-10 yearly to zero by implementing a safety framework that focused on identifying high risks, JSA implementation, training, and cultural enablers

Lang-Mekra North America Nov 2000 – Jan 2008

Lang-Mekra is a global provider of vision systems & trim components to the heavy truck and automotive industries. Specialization is medium and low volume manufacturing with high production variation and limited forecasting visibility.

Technical Services Manager/Logistics Manager/Production Support Manager

Established breakthrough improvements using Lean Six Sigma techniques, such as:

oDeveloped an efficient design & launch process for program management, reducing time-to-market from 3 yrs to 9 months

oReduced scrap from 5.2% of sales to 0.7% of sales

oImproved main line productivity by 472% per man-hr

oFormulated data algorithms to optimize materials forecasting, eliminating expedite costs and resulting in 100% on-time deliveries to 13 OEM plants in 4 countries

oEngineered a manufacturing process driven by ERP data algorithms for build-to-order line-sequencing, eliminating batch manufacturing

oApplied process error proofs that ensured 100% functional testing and eliminated all labeling errors across a dispersion of 1,400 active finished good assemblies

Managed production scheduling, material planning, utilizing MRP and JIT processes, following ISO/TS standards and guidelines

Developed detailed reporting metrics to track and improve overall production environments

Cross functional leader, working with all impacted areas to maximize efficiency

Managed teams responsible for developing new manufacturing work centers and integrating them into production environments

Analyzed and planned work force utilization, space requirements, workflow and layout of production equipment for maximum efficiency

Managed inventory analysis processes, variance reconciliation and reporting

Managed multi-plant functionality by balancing product-line supply and demand, cost structures and profitability

Managed forecasting development and analysis, supporting multiple production lines and broad customer base

Managed phase out plans for part number and inventory reductions

Managed ECN system to achieve seamless integration of part and product changes into production environment

Managed and controlled $4-6M finished good, raw and work in process inventory to achieve corporate inventory accuracy and inventory turn metrics

Managed operational departments with direct and indirect reports of over 270 people

Continuously develop business systems to achieve higher performance, corporate goals, and streamline decision making

Project manager of many corporate projects, including the implementation of global ERP system, and successful integration of ISO / TS 16949 quality standard

Plasti-Line Incorporated, Columbia, SC Nov 1999 - Nov 2000

Senior CNC programmer / Machine Shop Supervisor

AMBAC International, Columbia, SC 1994 – Nov 1999

Technical Services Supervisor


Business Degree University of Phoenix

Lean Manufacturing Certified TBM Consulting Group

Six Sigma Greenbelt Certified Master Solutions, LLC

Dale Carnegie Graduate Dale Carnegie Training Center

Masters Degree Knowledge Operations Management, Lean Systems Deployment

oProficient in ERP Software Platforms ( Baan, Trans4m, SAP, Infor LN ), Windows applications and Microsoft Office including MS Word, Excel, PowerPoint, Outlook as well as AutoCAD 2D drafting.

oTrained in Creative Leadership techniques, Time Study and Performance Rating Methods, Internal Auditing, 5S and Lean Manufacturing Principles, Strategic Thinking


I am a self-driven, strategic change agent, pairing strong technical acumen with adaptive communication skills in a natural working style as a facilitator. By clearly establishing priority and focus, I balance immediate high-impact results with sustainable process-based improvements. While I exhibit and seek to inspire a highly driven work ethic, I am highly flexible, receptive to input, and capable of negotiating compromise to ensure collaboration and ultimately team success. I am looking for an opportunity to apply & expand my experience.

Contact this candidate