Sammie L. McCall
Driving Operational Excellence to Deliver Bottom-Line Results
Production Manager driving process improvements in manufacturing using operational excellence, lean manufacturing, strategic planning, project management and leadership development tools. Multi-customer operations management, cross-functional team leadership and productivity improvements consistently delivered.
Strategic Planning & Execution
Multi-Customer Operations Management
Manufacturing Process Improvement
Expense Planning & Control
Hanes Brand Inc, Kings Mountain, NC Mar 2018 to present
Responsible for ensuring all Processes of the department are accomplished including: Wave Management, Slotting, Order Picking, Special Order Handling, Shipping and Rack Maintenance. Responsible for processing orders received from Customer Service with the designated Ship Windows, coordination of New Styles, Pipes and Fashion Colors on time at high service levels and within Specifications of Vendor Guidelines. Ensure all functions are completed in a timely manner while maintaining Picking Quality and Accuracy. Accurate Inventories and Budget Control, support management established KPI's, Projects, and Programs. Organize and Develop Departmental Staff and set the Standard for Continuous Improvement. All other required functions and activities not specifically mentioned to support the Facility and Supply Chain.
Lap Tech Industries Inc, York, SC Jul 2017 to Nov 2017
Responsible for plant organization, scheduling and manpower deployment. On time delivery(OTD), drove productivity and throughput by ensuring that machine cycle times were achievable and hour by hour targets were achieved. Deployed floor marking scheme to establish boundaries to prepare team for visual factory and 5S+1 initiative. Drove 5S and 5 Why training for team members down to the operator level, took ownership for recruitment, retention of indirect labor(IDL) and direct labor(DL) staffing and training. Developed weekly scheduling tool to track on time delivery and 90day plan to track and report team's progress. Created a relationship with customers which allowed open communication concerning any issues including on time delivery and quality.
Flextronics, Charlotte, NC 2007 to 2016
Manufacturing Operations Supervisor
Implemented Zero Defect program utilizing Lean Manufacturing principles to reduce the number of defects in assembly and test cells by 50% and Zero defects reaching the Customer within 3 months. This allowed the customer to reduce expenses by $60,000 per month and move more business to Flextronics Charlotte. Upgraded staff talent and cross functional team performance. Created Team Cell structure for improved process and product flow. Developed Supervisor weekly checklist for the entire factory focusing on Visual Factory and 5S+1. Instituted assembly and test TAKT and HPU for the entire factory to improve output. Monitored and controlled DL spend as a percentage of VAM for all assigned customers. Managed Semi-Finished Goods(SFG) for all assigned customers (inventory, distribution, weekly cycle counting and reconciliation). Monitored and maintained scrap(NCM) for all assigned customers to below .05 percent of the total revenue. Managed teams that were responsible for 70 percent of the total site revenue. Maintained On Time Delivery(OTD) for all assigned customers at or greater than 97 percent. Prioritizes production schedules based on product introduction, equipment efficiency, and materials supply in order to meet customer requirements. Maintained safe and clean work environment by educating and directing assigned personnel on the use of all safety equipment and resources and maintaining compliance with established policies and procedures.
Solectron Technology Inc., Charlotte, NC 1997 to 2007
Production Coordinator II
Reviews production schedules and related information and confers with department managers to determine material requirements, identify overdue materials, track and expedite material to meet production schedules. Communicates quality issues including shut down of the process if it's jeopardizing the integrity of STI's quality commitment. Performs system transactions to report movement of material between Manufacturing operations and into finished goods and tracks/reports daily progress of manufacturing orders against goal. Notifies Materials Project Manager of critical movement material and production situations that could impact schedule attainment. Tracks and reports some key manufacturing metric, such as cycle time against goal and/efficiency and assists in cycle time reduction and efficiency improvement efforts. Assist in the training of new employees.
Solectron Technology Inc., Charlotte, NC 1995 – 1997
Process Technician II
Assist the Test Supervisor with daily operation of test area. Trained test personnel in accordance with the appropriate policies and test procedures. Assisted in drafting and implementation of test area procedures. Collected data to determine root cause, isolated faults and determine the remedies for malfunctions of complex debug problems.
Solectron Technology Inc., Charlotte, NC 1993 - 1995
Test Technician II
Test and troubleshoot digital and analog printed circuit boards down to component level ensuring that production and quality standards are met. Inspected own work and that of others per applicable work instructions and standards. Maintained functional test equipment, trained other test technicians and operators. Empowered to shut down the process per the shutdown criteria as defined in the work instruction and institute the line screen process.
Radio Sound Inc, Louisville, KY 1992 - 1993
Engineer Lab Technician
Duties included assisting in the revision of existing products. Responsible for the design and building of interface cabling and creating the mechanical drawing for the Harley Davidson motorcycle and Arctic Cat snowmobile utilizing autocad. Member of Team RSI circuit design team responsible for functional debug of new products consisting of both analog and digital circuits.
Other Employment – Prior to 1993
United States Army, Fort Knox, KY 1976 - 1990
Duties included the direct supervision of four instructors. Writing and revising lesson plans. Classroom instruction, administering test to ROTC cadets, Armor Officer Basic students and Permanent Party staff and Initial Entry soldiers. Awarded the Army Commendation (3) and the Army Achievement (1) medals.
Education & Professional Development
AS Degree of Applied Science in Electronic Engineering Technology, RETS Electronic Institute, 4146 Outer Loop Louisville, KY 40219, 02/18/91 – 02/05/93
GPA – 3.58
Directors List 1991 - 1993
Operations Management, 2016
Project Management – Project Feasibility and Life Cycle course certificate, 2016
Shingijutsu Kaizen workshop, 2014
Corporate Lean Green Belt certification, 2013
Introduction to Federal Acquisition Regulation, CPCC, 2010
Lean Office, CPCC, 2009
Coaching for Success, CPCC, 2007
Managing Performance Problems, CPCC, 2007
Coaching for Improvement, CPCC, 2007
Statistical Process Control, CPCC, 2007
Kepner Fourie-Thinking Dimensions, CPCC, 2007
Design of Experiments, CPCC, 2007
Lean Manufacturing, CPCC, 2006