MICHAEL E. SEARS

252-***-**** • Rocky Mount, NC 27804 • ac7tv8@r.postjobfree.com

MANUFACTURING OPERATIONS/ENGINEERING MANAGER

PRODUCTION CONTINUOUS IMPROVEMENT TPM SIX SIGMA QUALITY MAINTENANCE

A dynamic leader experienced in Lean Manufacturing and Continuous Improvement within fast paced environments that brings enthusiasm and buy-in to cross-functional groups, improves efficiency, productivity, safety, reduces costs, and develops front line leaders while leading complex capital projects to accomplish organizational goals and deliver tangible results.

• Lean Manufacturing • Quality Assurance • Program Management

• Teambuilding / Mentoring • Project Management • Product Development

• Project Management • Forecasting / P&L • Customer / Vendor Relations

• Six Sigma / 5S / KPIs • Capital Projects • Presentations

• Continuous Improvement • EH&S Compliance • Report Writing

• Root Cause Analysis • ISO 9001 / TL 9000 • Inventory Management

• Proposal Preparation • SOP Documentation • Capital Budgeting

PROFESSIONAL EXPERIENCE

MANAGER – FACILITIES AND MATERIALS LS Cable & System U.S.A. • Tarboro, NC 2017 - 2018

LS Cable acquired Superior Essex Energy in 2017 and manufactures low and medium voltage cables

• Oversaw facilities and equipment maintenance, raw materials procurement, and logistics operations

• Opened a remote warehouse location to reduce freight costs and improve customer response time

• Played key role on supply chain team which resulted in reduced raw material costs of 10-15% by

locating and qualifying new suppliers for crucial materials

• Reduced freight costs by 20% by increasing load consolidation levels for full truckload (FTL) shipments

and for less than truckload (LTL) shipments by bringing on a new LTL logistics provider

• Improved maintenance effectiveness by revamping shift coverage, revising parts stocking, and

developing preventative maintenance schedule resulting in increased production and reduced downtime

ENGINEERING & PRODUCT DEVELOPMENT MANAGER Superior Essex Energy • Tarboro, NC 2015 - 2017

Superior Essex Energy is a division of Superior Essex and subsidiary of LS cable which began in 2015 and manufactures low and medium voltage power cables

• Managed process engineering and product engineering improving process and product reliability

• Led new product development and implementation at corporate level including redesign of low and

medium voltage power cables, which involved collaborating with cross functional department teams

• Developed plant budget spending of $90+ million (raw materials, utilities, labor) with $120M sales forecast

• Streamlined the product trials process for new products and increased effectiveness of communication

at corporate level to ensure company-wide agreement on the priority products

• Reduced defects in key plastic extrusion manufacturing department by 30% through improved data

collection and root cause analysis across all production departments

• Decreased plant utilities spending 15% by implementing energy savings to lighting, HVAC, and equipment

• Coordinated with equipment vendors to obtain quotes for capital projects, negotiated pricing, worked

on specifications (PLC controls, plastic extruders), purchased equipment, and supervised installation

• Maintained key supplier relations, negotiated existing pricing, and qualified new material suppliers

• Coordinated new product introduction with sales department to ensure specifications and accuracy of

production timelines, and facilitated plant tour meetings with customers

Superior Essex Communications Tarboro, NC 1998 - 2015

OPERATIONS MANAGER 2013 - 2015

• Oversaw engineering, maintenance, production, and quality assurance functions for new business unit

• Developed new business unit from scratch into a stable, profitable product line

• Led cross-functional group of project team managers in improving first-time product quality yields by

31% over two-year period, and decreased scrap 26% over a year resulting in record-setting performance

ENGINEERING MANAGER 2005 - 2013

• Directed engineering, product development, plant-level raw materials, and maintenance activities

• Turned around ineffective cost-reduction program into $8.3 million cost savings over a five year period

QUALITY MANAGER 2001 - 2005

• Achieved lowest rate of customer complaints over four years by collaborating with production team

• Implemented processes for new TL 9000 Certification in addition to maintaining existing ISO 9001

• Developed new internal audit system and trained staff for auditing compliance to achieve quality standards

• Upgraded QA testing plans to reduce in-process defects and technical customer complaints

• Maintained vital relations with customers by communicating on quality issues and conducting onsite visits

PRODUCTION SUPERINTENDENT 1998 - 2001

• Managed a large, 24/7 manufacturing organization with 325 employees in 425,000 sq. ft. facility

• Drove implementation of new processes reducing direct labor costs by over $1.2 million annually

Superior Cable Elizabethtown, KY 1995 - 1998

PRODUCTION MANAGER 1997 - 1998

MAINTENANCE MANAGER 1995 - 1997

Alcatel Elizabethtown, KY 1989 - 1995

MANUFACTURING DEPARTMENT MANAGER 1991 - 1995

PROCESS ENGINEER 1989 - 1991

EQUIPMENT / MACHINES / PROCESSES

Plastic Extrusion, Aluminum & Copper Wire Drawing, Assembly, Continuous and Batch Manufacturing

COMPUTER / TECHNOLOGY

Microsoft Office, Word, Excel, PowerPoint, Access, Project, MRP (material / inventory reports)

MILITARY

United States Navy Reserve – Retired Nuclear Submarine Officer - Charleston, SC

EDUCATION

Bachelor of Science, Mechanical Engineering – Florida Institute of Technology

Bachelor of Science, Engineering Physics – Jacksonville University

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