Charles J. McManus Phone 608-***-****

*** **** **** ****** ac91cv@r.postjobfree.com

Evansville WI. 53536 www.linkedin.com/in/charles-mcmanus-LeanManufacturing-Operations-Material-Professional

Professional Summary

25 years of comprehensive Operations, Materials and Logistics management experience in both manufacturing and distribution environments.

Operations leadership roles in Analytical instrument assembly / EMS / Printed Circuit Board Assembly, Metals Fabrication and Distribution / Logistics

Lean Manufacturing leadership using Toyota System Production philosophies to drive continuous improvement

Quality / QMS Operating Environments ISO 9001-2015 & ISO/TS 16949:2016

Lean Accomplishments:

Inventory Reduction, Thermo Fisher: Reduced inventory $8.5 million over 10 year tenure. Worked with Operations Team to deploy consignment, kanban, PFEP, reduced cycle time 4-6 weeks across entire breadth of product line offering, addressed scrap and returns process finding use & dispositioning $850 in stagnant inventory. Suntron: Reduced inventory $1 million during tenure by deploying consignment inventory, bar coding improving material handling efficiency and accuracy, standard work and master data integrity. Cleaver Brooks: Reduced inventory $6 million over 10 years tenure. Worked with Operations Team to deploy consignment, kanban PFEP, reduced cycle time 8-10 weeks across entire breadth of product line offering, addressed scrap, found use & dispositioned $1 million in stagnant inventory.

Cycle Time Reduction, Cell Design / Material Flow, Line Balancing, & 5S, we not only reduced inventory (noted above) but reduced resource requirements. Over tenure @ Thermo Fisher Manufacturing / Materials aligned headcount were reduced by 55+ resources. During same period, revenue increased $45 million, three new product lines were consolidated @ Madison and 10 new products were introduced, including 3 instruments for another division. Bringing our annual revenue to $200+ Million

TPS (Lean) & PPI’s Lean Enterprise Systems: deployed Tiered Stand-up Meeting Manufacturing Methodologies, focusing on daily metrics, data collection to identify & resolve quality, performance issues and identify improvement opportunities leading to reduced lead times, increased throughput capacity, improving quality and on time delivery performance.

5S, and Kaizen (Continuous Improvement): improved performance of each manufacturing workstation, addressing ergonomic, safety, material flow and handling issues, fixturing and tool requirements in a participative Team environment.

Implementation of Preventive Maintenance programs to address and reduce downtime. Implemented on-line manufacturing instruction, Training Matrices / records

Value added perspective, reduced required resources while improve or maintain service and production performance levels.

Quality Improvement: Through APQP, process mapping, FMEA, Control Plans & CAPA have worked to improve quality, diligently collecting & analyzing data, strengthening controls and procedures and related training regimen to insure process capability and quality performance consistency.

Strategic Planning and Implementation:

Experience with Greenfield start up, participated in the development and implementation of strategic plans for closing CB’s Lebanon Manufacturing facility & transition operations to Thomasville GA. Assessed capacity needs, completed transition planning for Materials support, collaborated with Engineering to support product transfer. Successfully executed the startup of Materials function and systems, transfer of $4.5 million to Thomasville, and concurrently reduced warehouse space requirements 40%.

Multiple iterations to develop and implement comprehensive plans reformatting Materials and Aftermarket Teams:

oMaterials function, constructed office space to consolidate planning and purchasing functions located in separate buildings, dramatically improving communications, collaboration, responsiveness and results improving customer satisfaction and evolving to a reduction of 3 full time resources.

oAftermarket, developed autonomous Regional Self Directed Teams through focused cross training, realizing a staff reduction of 2 employees,

oDeveloped plan to combine Production and Aftermarket warehouses into a single combined warehouse, reducing a Warehouse Supervisor and 4 material handling positions.

Key member of Team tasked to plan and execute consolidation of Thermo Fisher’s newly acquired Life Sciences operation into our facility. Worked with Life Science Team to set up suppliers supporting utilities, gas supply, maintenance, protective equipment, water treatment and the logical transition / closure of supporting purchase orders.

Extensive experience with NPI successfully launching numerous new products with Thermo Fisher, and Morton Metalcraft supporting Deere Hitachi and Caterpillar new skid steer products. Adhered to NJSU procedures for Caterpillar. Used FMEA protocol to develop control plans to improve performance and quality.

Analyzed and created Operating and Capital budgets, sales objectives, profit improvement / cost reduction initiatives.

Systems, Materials, Production, Inventory and Cost Control:

Experience with multiple MRP / ERP systems, (including SAP). Multiple iterations / experience transitioning / installing integrated MRP systems, training, and systems initialization.

Reduced inventories through implementing multiple internal / external Kanban / JIT Supplier relationships covering major purchased commodities (Plate, Piping, and Electrical) and reduction of supplier base. Designed and implemented Kanban systems to replace traditional work order system for repetitive used internally manufactured parts and components.

Worked with Engineering to facilitate restructuring and flattening of Bills of Material, allowing for:

oCreation of “supermarkets” of generic BOMs allowing for late configuration process enhancing responsiveness to customer demand,

oUsed late configuration methodologies to facilitate quick response to customer demand and reduce inventory.

oReduced labor intensive time consuming transactional requirements of fully indented BOM structure

Reduced Material cost through supply chain value analysis incorporating supplier participation, hybrid supplier stocking programs, commodity negotiation, & reduction of material and logistics costs.

Human Resources:

Multiple iterations of reorganizing Materials functions to improve performance, responsiveness and results, aligning personnel to support autonomous Teams, with standard work supported by metrics evaluating effectiveness & results.

Designed, implemented and administrated competitive wage and benefits program at Kann, & Sampson creating job descriptions, wage structure, incentive programs, employee goals / objectives, implementing new employee indoctrination, established or reinvigorated safety programs. Created and launched Safety Team’s focus on housekeeping, hazard recognition and corrective action.

Initiated tracking of absenteeism and turnover rates. Launched aggressive policy adherence to address excessive casual absenteeism, developed and implemented employee handbooks and Drug Free workplace Policies

Evaluated, coached Team members recognizing stellar & addressing poor performance. Replaced / enhanced reporting staff where necessary.

Developed working relationship with local community colleges as a resource for talent and training employees in quality, lean manufacturing and safety utilizing state funding.

Work History, Assignments and Accountabilities

2018 to April 2019 SSI Technologies (an Amphenol Company): An IATF (ISO/TS 16949:2016) Certified OEM Manufacturer of sensors serving the automotive / truck / motorcycle, construction, power generation equipment and hydraulic marketplace. SSI Revenue $130M.

Manufacturing Mgr. Responsible for: Manufacturing, Driving Lean Manufacturing and cost reduction initiatives, On Time Delivery (>95%), facilitate achieving inventory, warranty reduction targets, support NPI, Quality excellence for 3 product lines.

2008 Thru 2018 Thermo Fisher Scientific: An ISO Certified OEM Manufacturer of Analytical Scientific Equipment, Applied Biosystems, Laboratory Supplies and Support Services. The Madison Manufacturing facility produces high end scientific spectrometers generating in excess of $200 million annually

Manufacturing Mgr. Responsible for: Manufacturing, Manufacturing Engineering, Drive Lean Manufacturing and cost reduction initiatives, On Time Delivery (<95%), facilitate achieving inventory, warranty reduction targets, support NPI, Field Install excellence, Aftermarket service support for 6 Instrument Value Streams..

2003 Thru 2008 Suntron (now Benchmark.): An ISO Certified EMS provider / manufacturer of Printed Circuit Boards and integration for custom electronic assemblies servicing the industrial, aerospace / defense, construction and agriculture industries. The Garner IA. Facilities specific Niche high mix low volumes. Employees: 55 employees with annual sales $15 Responsible for: Manufacturing 2 shift operation 4 Supervisors, Materials / Purchasing (4 buyers, 1 planner), Engineering (2 Engineers, 1 Draftsperson), Materials Management, Production & Inventory Control, Warehousing and Logistics. Profile: 4 SMT production lines (MYDATA Equipment), 2 through-hole axial chip inserters (Universal), 2 wave solder lines (one Pb Free, ICT, AOI, functional testing, Conformal coating, Potting and integration. Primary customers Thermo Fisher, Vermeer, Raytheon, Deere

Operations Mgr.

Prior to 2003 General Manager for Morton Metalcraft & Samson Supply and Manufacturing: Manufacturers of sheet metal and structural fabricated products, supplying the Construction, Agricultural, and Industrial OEM Marketplace serving diverse set of customers including Caterpillar, Deere/ Hitachi, Terex, and Elgin Sweeper Responsible for: Manufacturing, Purchasing, Order Processing, Accounting, Human Resources, Quality Maintenance, Sales and Engineering, Production / Inventory Control, Warehousing and Logistics. Functional operations include CNC Laser, Turret / Plasma Presses, Press Brake, Machining, Manual and Robotic Weld, and Electrostatic Powder Paint.

Materials & Lean Implementation Project Manager Cleaver Brooks: A Manufacturer of industrial and commercial boilers and providing aftermarket sales and support through a worldwide distribution network predominately to the heating, food processing, institutional and cleaning industries. Responsible for: Purchasing, Order Processing, Production Control, Warehousing and Aftermarket Directed all operations supporting boiler configuration, material purchase and Inventory Control, shop floor control, customer order entry, processing, warehousing, and distribution logistics including traffic, both domestic and export. I was the Lean Implementation Project Manager using KanBan, 5S and Kaizen Workshops supporting cycle time reduction to dramatically reduce customer response time and equally improve production efficiencies and quality results.

Education: Bachelor of Business Administration, University of Wisconsin, Whitewater, WI .

Course of study: Production and Materials Management, member Law Society.

Special Skills: Experience with multiple ERP Systems (SAP, Plex, Epicore, Mapics), Microsoft office software, Familiar with domestic (including heavy haul specialized carriers) and international transportation logistics including associated documentation and finance.

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