Manager Plant

GENE HARNED

PHONE: 630-***-**** *********@*******.***

7N050 Ridge Line Rd.

Saint Charles, IL. 60175

OPERATIONS MANAGEMENT

Operations Management Quality Process Control & Productivity

Ability to lead strategic manufacturing processes, capturing the “big picture” of shareholder expectations.

In-depth integration with diverse experience in operations management, business development strategies, and lean manufacturing processes.

Outstanding Professional skill, leadership, and ceaseless efforts resulting in major contributions to the effectiveness and success of manufacturing operations.

Intelligence position, transforming businesses from plant “start-up” operations to driving efficient productivity.

Inventory & Asset Management

Project Controllership

Brilliant Leader & Communicator

P&L Financial Controls

Superior Supervisory Skills

Articulate Cultural Engagement

Fosters Teamwork

Motivates Subordinates

Operational Efficiency

High-level analysis to deliver production solutions aligned with organizational objectives.

Lean manufacturing methodologies with measurable “Return of Investment Capital” results.

Outstanding negotiator with ability to influence favorable outcomes for all concerned parties.

PROFESSIONAL EXPERIENCE

BERRY GLOBAL, INC. Aurora, IL.

Operations / Production Manager (Multi Site) Oct 2016- Present

A global manufacturer and marketer of plastic packaging products with over 140 manufacturing sites worldwide and over 25,000 employees.

RESPONSIBILITIES:

Complete P&L responsibilities for assigned departments.

Facilitating several CI teams all focused on cost reduction.

In process of implementing several lean projects designed to develop staff and engagement of associates.

Work with entire staff developing a lean culture in daily operations. Using lean tools to track, maintain and improve KPI’s

Point person for all employee related concerns, training, hiring, promotions and disciplinary issues along with H.R.

Developed “standard work” using photos, diagrams and templates presenting work instructions in a distinct manner to ensure “current best way” is employed.

Work closely with technical department identify areas for cost reduction.

Oversee all plant functions working with department heads setting short term and long term goals.

Worked closely with Quality Team implemented escalation policy to ensure standardization of how nonconformance product is identified, quarantined and corrective measures implemented.

CUSTOM BLOW MOLDING, Aurora, IL

Plant Manager July. 2014 – Aug. 2016

CBM a manufacturer of plastic packaging, containers and parts, CBM is the #1 packaging supplier for sports nutrition and supplement industries in North America.

Accomplishments:

Achieved complete Plant “start-up” operations, including hiring of staff and contractors, approval and implementation of business plans, permitting, and procurement, installation and operation of all plant equipment.

Ensured timely installation of axillary plant equipment, per code and under budget, administering and managing award of vendor bids, including entire outlay of front offices, plant floor, eight blow molding machines and support equipment.

Utilized existing equipment, refurbishing and upgrading several machines, replacing work parts and ensuring staff had machines ready for the startup schedule.

Successfully managed the installation of all new machines, ensuring cycle times and budgets were met, working with Kautex and Bekum technicians.

Developed and implemented maintenance PM programs, all Sop’s, along with Tiered audits.

Ensured that proper training and safety practices were followed, supervising tooling changes with new associates.

Developed associate “onboarding” plans for new hires, trained all new floor personnel, and develop standard work for job classifications.

Optimized warehouse space, while maintaining product integrity, developing layer auditing system for finished goods and standardizing finished goods unitization.

Focused on high-risk and behavioral items, implementing” STOP” Behavioral based safety training programs.

Successfully handled all employee grievance issues, As well as the promotion and dismissal of employees.

Developed a “team centered” work environment for all shifts, working with the plant staff.

Introduced employee recognition programs to promote engagement.

Provided training, goal setting, and utilized an auditing system to measure results, introducing KPI’s to team members.

Spearheaded a” Floor up” and not “top-down” program for information sharing, shift to shift and department to department, for goal setting and problem resolution, utilizing visual aids for communication and introducing Tier process.

GRAHAM PACKAGING COMPANY, West Chicago, IL

Production & Operations Manager 2004-2014

Premier provider of manufacturing and packaging services to the world’s largest packaged goods companies, with 99 manufacturing facilities.

Accomplishments:

Ensured success of production operations, managing a 24/7 plastics blow molding operation with six supervisors and more than 100 associates.

With 18 production machines and daily output average up to 600,000 containers. Manufacturing platforms included Graham and Wilmington wheels, Techne, Uniloy, and Sipa machines.

Slashed costs with 30% improvement to efficiency, raising safety factors, driving CQI facilitation, and leading the first CQI team; project focused on design of a new production scrap handling system.

Successfully directed multiple departments including Maintenance, Quality, Planning & Scheduling, Accounting, Engineering, and Customer Service, with full responsibility for labor-management, product launches, R&D, customer relations, P&L, safety and employee development.

Improved equipment cycle time, safety, quality, cost control, customer response time and customer partnerships.

Utilized ERP system and MS Excel, managing inventory controls.

Spearheaded a” Floor up” and not “top-down” program for information sharing, shift to shift and department to department, for goal setting and problem resolution, utilizing visual aids for communication and introducing Tier I, II, and III, staff meetings.

Took part in the implementation of A3 system and formal PDCA problem-solving.

Improved output and crewing by 15%, redesigning and restructuring production lines to improve equipment cycle time through line layout improvements and equipment changes.

Increased efficiency by 10% while slashing labor cost by 18%, developing and implementing the DSC’s schedule tool for real-time responses and immediate insight into line performance.

Resolved equipment issues with Maintenance, scheduling PM time and job changeovers.

Covered all open positions while recruiting new replacement candidates for management positions such as plant manager and maintenance manager, with responsibilities including daily scheduling of work, prioritizing resources, ordering parts, emergency support, and handling prescheduled work.

Worked with SAP information system.

Working experience in all West Chicago Plants with Graham P171, P172, and P174.

GRAHAM PACKAGING COMPANY, West Chicago, IL

Operation Supervisor 1989-2004

Privately owned, premier provider of manufacturing and packaging services to the world’s largest packaged goods companies, with 99 manufacturing facilities.

Accomplishments:

Ensured success of manufacturing operations, training all department supervisors and operators as part of corporate improvement initiative.

Utilized lean manufacturing methodologies and tools for projects with a clear focus on Return on Investment Capital.

Achieved overall corporate objectives for continuous improvement, directing cross-functional teams as project leader, Including middle to senior management, engineers, planners, and technicians.

POWER PACKAGING COMPANY, Saint Charles, IL

Production Supervisor 1986-1989

Privately owned, contract food packaging company servicing numerous fortune 500 companies. Was heavily involved in numerous line start-ups as well as line qualifications. Worked at several different facilities as needed.

Accomplishments:

Achieved production efficiency of 96.7%.

Reduced labor by 30%, while maintaining efficiency.

Worked with plant management to redesign manufacturing processes, introducing cell manufacturing.

Overall 20% labor improvement during the first two years, improving manufacturing cycle time by analyzing all work

Successfully implemented a LEAN Six Sigma approach to ensure continuous improvement.

UNITED STATES NAVY, N.A.S. Jacksonville, Fla.

East Coast Search & Rescue Swimmer, Wet Crewman 1978-1982

Tasked with completing one of the most physically and mentally demanding military training programs in existence.

Passed Navy Physical Screening Test requirements for Navy Challenge Programs.

Assignments ranged from Rescue missions, Recovery missions, Humanitarian assistance and Operational support.

ADVANCED EDUCATION & TRAINING

TQM: Statistical Process Control

Management For Quality & Productivity

Quality: The Deeming Method

Facilitator Training: The Power of People Skills

& Change Management

DuPont “STOP” Behavior Based

Safety Facilitator Training

Organization Management

Bachelor of Science (BS)

AURORA UNIVERSITY

Aurora, IL

UNITED STATES NAVY, NAS Jacksonville, Fla.

East Coast (SAR)Search & Rescue Wet Crewmen

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