Guy W. Whalon
**** ******* *** *********, ** ****8
Cell: 224/241-4993
ac7ctv@r.postjobfree.com
MANUFACTURING OPERATIONS PLANT MANAGEMENT
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
PROFESSIONAL EXPERIENCE
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.
SHARPRINT, Chicago, IL
(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
SMURFIT-STONE CONTAINER, Schaumburg, Illinois
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.
SMURFIT-STONE CONTAINER, Houston, Texas
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.
OCCIDENTAL METALS & PAPER, Passaic, New Jersey
Paper and metal recycling services
Operations Manager 1988 -1992
Developed corporate programs to lease equipment, balers, shredders, roll-offs to Fortune 1000 companies.
EDUCATION and OTHER CREDENTIALS
BACHELOR OF ARTS IN ECONOMICS
Wilkes University, Wilkes-Barre, Pennsylvania
Courses, Seminars and Workshops
Lean Six Sigma Black Belt
Software Proficiencies
Microsoft productivity tools
DraftSight
MILITARY SERVICE
United States Army Honorable Discharge