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Plant Manager

Location:
Bakersfield, California, United States
Salary:
150,000
Posted:
November 21, 2018

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Resume:

John L. Caster

**** ********* *** #***

Bakersfield, CA 93308

317-***-**** (M)

ac7rfi@r.postjobfree.com

Education:

Associate Applied Science – Mechanical Technology Manufacturing, Black Hawk College, Moline, IL, 2000, 4.0 GPA

Graduated Summa Cum Laude Honors

Certifications – Six Sigma Green Belt Certification, Midlands Technical College, Columbia SC 2005, Lean Manufacturing /Six Sigma training- Midwest Training Institute, Indianapolis, IN, 2003, ISO 9001 Internal Auditor Training – IUPUI 2001, Hazardous Materials Training, CFR-49, IATA, IMDG, St. Louis, MO, 2003, Computer Numerical Control Machine Tool Programming, Black Hawk College, Moline, IL, 1998

Key Skills/Qualifications:

Multiple Site Management, Managed Safety, Quality, Productivity and Profitability for 4 factories

Plant, Production, Warehouse, Maintenance, Management and Supervisory experience

Plant Engineering Experience, Capital Projects, Major Repairs and Preventive Maintenance

Factory and Warehouse Consolidation/Closure and Expansion experience

CI, Lean Thinking and 6S instructor for multiple factories

Performance Management and Supervisory Development Training

ISO 9001:2008 Lead Auditor and Site Registration Accomplishments

Warehouse Management Systems Expertise, CAMBAR

RF (Radio Frequency) usage and Inventory Control

ADAGE and Oracle 11i ERP systems experience

Micromain, AS/400, DB2 and SQL usage

Microsoft Office – Word, Excel, Powerpoint and Outlook

LOAD CONFIGURATOR, AutoCad, Pro-Engineer, KRONOS

Professional Experience:

Ennis-Flint, Inc.

Plant Manager, Bakersfield, CA – 04/2017 to present

Direct Reports: 1 - Production Manager, 1 - Plant Administrator, 6 - Department Leads and 50 – 80 Hourly Associates

Provide leadership, mentoring, and evaluations for plant staff;

Propose improvements and changes in procedures to improve quality, safety, service, efficiency, and lead-time.

Maintain a clean and safe plant. Maintain good housekeeping taking plant to a world class level, including waste reduction, reduction in customer returns, and best practices.

Ensure proper staffing levels are in place, while meeting budget requirements.

Ensure proper training is being conducted with staff.

Ensure employee performance reviews are being conducted per Ennis-Flint guidelines.

Recognize and manage successful employee achievements and performance deficiencies.

Ensure production schedules are reviewed continuously.

Ensure proper notification is taking place in a timely manner with material shortages, quality, safety, and employees issues per Ennis-Flint guidelines.

Ensure a thorough understanding of quality requirements.

Understand and keep current on technology of plant.

Ensure there are scheduled and conducted production, quality, and safety plant meetings per Ennis-Flint guidelines.

Ensure compliance to all safety, health, and environmental requirements are being administered per Ennis-Flint guidelines and with local, state, and federal regulations.

Ensure any injury is dealt with immediately in an appropriate manner and reported per Ennis-Flint guidelines.

Ensure preventative maintenance practices and procedures are being completed per Ennis-Flint guidelines.

Optimize plant operation cost and meet operating budget while improving production yields.

PPG Industries Inc.,

Plant Engineering Manager – Reno, NV 8/2013 to 4/2017

Direct Reports: 1 - Senior Process Control Specialist, 1 – Maintenance Coordinator, 6 – Maintenance Mechanics

Provide a safe and healthy work environment for all employees through proper maintenance of equipment and facilities and elimination of health hazards to prevent work stoppage and time loss due to accidents, while ensuring adherence to all applicable environmental, health and safety regulations, standards and policies.

Provide leadership, develop and implement management systems to ensure safe work behavior by employees.

Manage a 2 shift, 5-day Maintenance Support function (with occasional weekend work as necessary) for the Reno Plant. Ensure that each Maintenance Department employee understands and adheres to all company policies and procedures regarding safety, health and the environment and that the proper training programs are in place to ensure that all applicable standards are met.

Effectively lead associates, encouraging a continuous improvement of individual performance while maintaining the operating philosophy of Reno Management. Comply with all EEO policies and procedures.

Provide plant engineering and maintenance support for manufacturing plant approximately 1000 SKUs for paint products representing 10 MM gallons to meet customer requirements and plant goals.

Efficiently develop and utilize people, equipment, materials, utilities and budget to meet Strategic Business Unit (SBU) requirements for safety, environment, quality, labor and expense.

In cooperation with local staff, plan, organize and manage the engineering and installation of specific projects to meet business needs in growth, maintaining existing capacity and/ or improve our position in safety, cost or quality.

Drive continuous improvement in OEE for high speed filling Lines, maintain process control automation (PLC and DSC) for paint making operation and implement solutions to improve overall productivity.

Provide network assistance and leadership for plant Maintenance and Engineering projects at other North American Architectural Coatings sites.

Develop and document best practices and procedures for use across the Architectural Coatings NA network

Accomplishments:

Managed multiple projects - Capital and Expense on time and under budget

Managed CMM System and full operation of Maintenance of facility

Operations & Manufacturing Director – Chicago, IL 5/2007 – 8/2013

Direct Manufacturing of General Industrial Liquid Paints and Specialty Coatings for the Aerospace, Automotive, Mirror, Conductive, Sign and Temporary Protective Coatings Markets

Direct Reports: 3-5 Plant Managers for North American Liquid plants

Directed and managed activities for 3-5 chemical manufacturing plants responsibility for achieving budgeted goals and metrics, including:

Major Repairs, Preventive Maintenance, and Capital Installations

Safety, Quality, Productivity and Shipping Metrics

Participate in Union Contract negotiations

Coordination of interaction of plants with Human Resource and Laboratory Managers

Continuous improvement activities associated with ISO and daily site operations

Review P/L statements for operations, and forecast data to determine department or division progress toward stated goals and objectives

Plan,develop, and implement new methods and procedures designed to improve production operations, minimize operating costs, and maximize the effectiveness of labor and materials

Prepares department budget and monitors expenditure of funds in budgets

Confer with VP and other administrative personnel to review achievements and discuss required changes in goals or objectives resulting from current status and conditions

Prepare and Coordinate completion of Capital plans that strategically align with corporate goals and objectives

Accomplishments:

Participated in ISO 9000/2001 - Certification of Illinois plant, 2/2008

Coordinated ISO 9001-2008 – Certification of New York Plant, 6/2012

Successful Plant Consolidation in 2008, Gary

Valspar Industrial Coatings,

Production Manager, Indianapolis, IN 4/2006 – 4/2007

Manufactured Liquid Paints and Stains for the Automotive and Architectural markets

Direct Reports: 5 supervisors and a Inventory Coordinator

Indirect Reports: 62 union hourly employees

Operation: 5 day, 24 hour, 3 shift make to order (JIT) batch production process

Lead manufacturing safety improvement efforts

Lead efforts to reduce late production batches

Reorganize manufacturing headcount to increase daily throughput

Improve production quality for improved batch variance results

Control production supply costs and minimize waste generation

Recognition of supervisor/employee accomplishments and provide directives for improvement

Approve/Order equipment and production supplies

Order/Request equipment and facility repairs/improvements

Communicate with plant, quality, technical and warehouse management and other key staff personnel to facilitate meeting daily shipping/production requirements and coordination of special projects

Identify cost reductions areas and other improvement opportunities

Complete performance appraisals on a bi-annual bas

Production Manager, Moline, IL 7/2003 - 4/2006

Manufactured Liquid Paints and Coatings for the Industrial markets

Direct Reports: 3 supervisors

Indirect Reports: 64 non-union hourly employees

Operation: 5 day, 24 hour, 3 shift make to order (JIT) batch production process

Lead manufacturing safety improvement efforts

Improve production quality for increased batch variance results

Control production supply costs and minimize waste generation

Recognition of supervisor/employee accomplishments and provide directives for improvement

Approve/Order equipment and production supplies

Order/Request equipment and facility repairs/improvements

Communicate with plant, quality and warehouse management and other key staff personnel to facilitate meeting daily shipping/production requirements and coordination of special projects

Identify cost reductions areas and other improvement opportunities

Complete performance appraisals on a bi-annual basis

Warehouse Manager, Moline, IL 1/2003 – 7/2003

Indirect Reports: 16 non-union hourly employees

Operation: Main plant Raw Materials warehouse and Off-site Finished Goods

Lead daily shipping safety huddles

Lead efforts to reduce inventory parts reduction

Improve inventory organization and reduce inventory variance

Control costs and minimize waste

Approve/Order equipment and shipping supplies

Order/Request equipment and facility repairs/improvements

Conduct monthly audits to identify cost reductions and other improvement opportunities

Complete performance appraisals on a bi-annual basis

Accomplishments:

Graduated from the Valspar XML3 (Excellence in Manufacturing Leadership) class

Modified and Implemented Skill Certification training guides and training matrices for new employees

7 successive months of exceeding On-Time delivery performance goals

No department Lost time or Recordable incidents, recently celebrated 5 years (June.03.)

Coordinated Safety Awareness Banner’s through dept. contest

9 successive quarters without any recordable injuries

Increased yearly productivity levels 2 years running

Achieved multiple plant production records - Yearly, Monthly and Daily

Nestle PURINA Petcare Co.

Warehouse Supervisor – Davenport, Iowa 8/1996 to 12/2002

Manufactured and Distributed Pet and Human foods for Consumers

Direct Reports: 2 Clerical employees, 30 non-union hourly employees

Indirect Reports: 2 offshift supervisors and 60 non-union hourly employees

Operation: 5 day, 24 hour, 3 production and shipping

750,000 Total Sq Ft On and Off Site Warehouses and Shipping

Monitor and maintain sanitary conditions according to GMP’s and AIB standards

Communicate with production management and other key staff personnel to facilitate meeting daily shipping/production requirements and coordination of special projects

Conduct monthly safety training, identify cost reductions and improvement opportunities

Served on Plant Emergency Organization and Safety Committees

United Way Loaned Executive Program (1999 Campaign). Team surpassed a record $7.9 million dollar goal.

Participated in United Way Fund Distribution 2000, Outcomes Measurement Program basis

Accomplishments:

Meets or Exceeds ratings on individual performance ratings

Inventory fill rates of 99.5% (pure case fill) and Delivery rates of 95+% on-time

Inventory Variance of .07-.08%, Inventory of 50,000 + unit loads –both DC’s 560,000+ Sq. Ft.

Received promotion from 2nd shift Supervisor to 1st shift Department Supervisor

Coordinated Warehouse Expansion projects

Developed and maintained A,B,C Warehouse lay-outs

Certified Forktruck Trainer/Tester

OSHA 40 Hour Class and re-fresher courses

Attended HAZCOM, HAZWOPER and D.O.T. HAZMAT classes

Served as a PEO and Safety Committee Member

Perfect attendance

First-Aid and CPR instructor

Affiliations

Society of Manufacturing Engineers - 1995 to 2002

Accomplishments:

(Academic Scholarship Recipient - 1999)

Military Experience

Iowa Army National Guard - 6/1984 to 6/1992

12B20 Combat Engineer, Sergeant E-5

Secret Security Clearance

Honorable Discharge

Accomplishments:

Awarded Certificate of Commendation

Primary Leadership Development Course Training

Instructor Training Course Training

References:

Available upon Request



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