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Plant Manager

Woodstock, IL
October 11, 2018

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Guy W. Whalon

**** ******* *** *********, ** ****8

Cell: 224/241-4993


Strategic Planning - P&L - Asset Management - Production Planning - Black Belt Lean Six Sigma Purchasing - Inventory - Quality Assurance - ISO 9001 Standards - DraftSight

AIB Coordinator - Process Improvement - DMAIC Analysis – EHS Manager

Developed high performing teams

Proven change agent

Black Belt Lean Six Sigma

Cut waste by 40%

Achieved 0 Accident Rates

Re-design of Departments and Work Cells to improve Productivity


FETCO, Lake Zurich, IL

(Metal Forming and Electro-mechanical assembly of Beverage Dispensing Systems)

Manufacturing Manager 2017---present

6 Direct Reports: Fabrication, Welding, Electro-Mechanical Assemblies, and Shipping/Receiving

Improved OTD 85% to 98%.

Managed Daily responsibility of all manufacturing departments and processes

Established Visual Management System of KPIs to improve Safety, Waste, 5S, and Productivity

Champion, Coach, and Mentor of Kaizen events: 5S, SMED, & TPM to reduce all forms of waste

Developed and implemented the conversion of 2 major manufacturing lines to “1 Piece Flow” lines

REVCOR, Carpentersville, IL

(Metal Stamping: Manufacturer of Industrial and Consumer Air Moving Equipment)

Lean Manufacturing Manager 2011---2017

6 In-Direct Reports

Implementation of Toyota Production System for a Lean, Visual, and Daily Management System

Increased Parts per Hour by 20-47% per Work Center

Daily Staff Gemba walks to review our production constraints and opportunities.

EH&S Leader, responsible for implementing new the new GHS for SDS system. Filed all EPA reports to Federal, State, and Local municipalities.

Lean Champion of numerous Kaizen events: 5S, SMED, TPM, and Vrk.

Monitor of overall plant performance for production, quality, and safety standards.

Reduced Set up Times by 56% thru SMED processes and training Supervisors and Leads.

Project Manager for multiple company acquisitions and full integration into our Business model.

Project Manager for a new, multi-million dollar manufacturing line.


(Printing company for the garment industry)

Director of Operations 2010-2011

Restored company to profitability after 3 years of losses

Implemented a Lean Mfg process that reduced waste from 3.8% to 2.0%.

Hired and trained a Staff of 8 Direct Reports

Implemented Daily Staff Gemba walks to review our production and support role KPIs.

Lean Mfg Champion of dozens of Kaizen events to improve Quality, Process, and Production Efficiencies.

Coordinated plant activities inclusive of production scheduling, quality, maintenance, and purchasing through planning with department supervisors to insure that manufacturing objectives were accomplished in a timely and cost effective manner.

Implemented cost effective measures to reduce operating expenditures, manpower, wages, and salaries.

Established and monitored overall plant performance for sales, production, quality, and safety standards.

Taught and implemented 5S programs for shop floor organization and plant cleanliness among plant personnel.

TAG, INC., Huntley, Illinois

Consultant 2008-2010

Conducted and implemented Lean Manufacturing training classes in Value Stream Mapping Standard Work, 5S, SMED, and Improvement and Visual Management.

Facilitated +100 of Kaizen workshops to improve production and business processes

Change Agent, Coach, Facilitator, and Trainer


Manufacturer of flexible packaging products (extruded and laminated roll stock, 6 color flexographic printing, pouches, bags, and thermoformed trays) for the Consumer and Pharmaceutical Industries

Plant Manager 2004 - 2008

Deliver energy, insight, technical expertise, financial acumen and organizational leadership to achieve key performance goals for a production unit of a Fortune 1000 firm. Developed policies, practices, standards and systems governing scheduling, customer service, quality, maintenance, shipping and receiving. Experienced Quality Leader in extrusion coating, laminating, slitting, and flexographic printing. Implemented Quality review and JIT purchasing programs to reduce waste and expenses. Directed a team of 6 supervisors in Continuous Improvement and managed 135 personnel.

Optimized P&L results on $42,000,000 in annual income; developed opportunities within existing accounts that boosted sales 27% and saved $400,000 in yearly raw material purchases.

Implemented a Lean Mfg process that reduced waste from 15% to 10% and cut $5,000,000 from material costs; saved $650,000 with SMED and trimmed $150,000 from preventive maintenance expense.

Established a Six Sigma Production environment based to improve quality and customer satisfaction; this reduced our Returned Goods from 2.2% to 1%

Implemented Daily Staff Gemba walks to review our production and support role KPIs to solve bottlenecks imposed by internal or external forces.

Lean Mfg Champion of 100s of Kaizen events to improve Quality, Process, and Production Efficiencies.

AIB Certified Plant: Implemented and wrote AIB Training and Checklist Plan resulting in 4 years of an audited “Superior” AIB rating.

SMURFIT-STONE CONTAINER, Vacaville, California

Manufacturer of Industrial and Consumer Paper Products & National Recycling services

Plant Manager 2002 - 2004

Controlled budgets and purchasing. Established administrative and production infrastructure to maintain and improve and maintain plant sales, improve safety record, and right size the work force.

Trimmed the workforce by 25%; propelled a 25% rise in sales to $4,000,000; improved on-time delivery from 90% to 99%.

Introduced shop floor controls that reduced waste by 90%; implemented a Kanban program for all supplies. Accident-free record throughout tenure.


Manufacturer of Industrial and Consumer Paper Products & National Recycling services

Product Manager 1999 – 2002

Directed product line development for a Fortune 500 enterprise with sole accountability for attaining goals for market share, revenue and profitability at 3 manufacturing facilities. Motivated a team of 4 direct reports and orchestrated procurement, conversion and sales functions. Managed key business relationships. Developed sales and technical documentation. Administered 3 P&L budgets.

Created marketing/sales materials; promoted cross selling and product bundling; won national contracts and built sales to $2,500,000 with a 52% profit margin in 18 months.

Increased conversion efficiencies every year in every plant by 20% or more.

Developed Job Safety Analyses (JSAs) and Work Instructions (WI); blended the Hourly production staff into the Safety Team and had no employee accidents.

GEORGIA PAPER TUBE, West Chicago, Illinois

Converter of Paper Products and regional Recycling Services

General Manager 1995 -1999

Maximized P&L results for a $3,500,000 business; coordinated new plant set-up, optimizing workflow; installed equipment and instituted maintenance programs that reduced downtime.

Wrote and implemented all: administrative, support, and production programs to support the infrastructure.

PST CORP, Atlanta, Georgia

Manufacturer of Paper Products and regional Recycling Services

General Manager 1992 -1995

Promoted sales and headed production operations for a start-up venture

Brokered the sale of the company to Georgia Paper Tube in 1995.


Paper and metal recycling services

Operations Manager 1988 -1992

Developed corporate programs to lease equipment, balers, shredders, roll-offs to Fortune 1000 companies.



Wilkes University, Wilkes-Barre, Pennsylvania

Courses, Seminars and Workshops

Lean Six Sigma Black Belt

Software Proficiencies

Microsoft productivity tools



United States Army Honorable Discharge

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