Plant Manager or Director

D

OUG STUNTZ Change Agent • Business Operations

Lean Manufacturing Orchestrator

Provide improved bottom line results and KOIs leading & improving organizations while promoting synergistic teams

Rich mix of continuous improvement development, operations, and finance for multi-million dollar organizations. Diversely experienced from start up to work out, turn around and rapid growth – resolving long-standing problems and creating sustainable solutions that improve operational efficiency. Leverage expert analysis and insight to promote lean approach and team environment that drives organizational improvements and instills best practices. Objective and progressive with dynamic leadership and business acumen to produce extraordinary results. Selfless advocate and masterful persuader.

AREAS OF EXPERTISE

Executive Decision Maker & Fiscal Champion

FSMA, FSPCA, AIB and HACCP Certified

Multi Site Operational Leadership

Team and Safety Trainer

Green Field Facility Startups

Corporate Planning & Strategic Developer

Lean & Six Sigma Practioner

P&L Management and Budgetary Direction

EDUCATION & TRAINING

B.S., Manufacturing Management Science, Virginia Tech, Blacksburg

SAP, SQF II, OSHA 10, QHSE, Dale Carnegie, Kaizen and LSU Better Processing School

EXPERIENCE & ACHIEVEMENTS

Wright Group, Crowley, LA

2017 – 2019 Company provides vitamin / pharmaceutical powders and enriched rice to top food companies like Kraft, Hormel and Treehouse.

Plant Manager & Operations Director

Provide operational and lean manufacturing expertise to upright manufacturing and ensure compliancy to FDA, USDA and OSHA.

Turnaround and Revitalization:

• Led the successful turnaround of a distressed flag ship plant over an eight period hiring and training new staff and employees while developing a Kaizen culture. Ultimately reduced production from 7 to 5 days and increased kilograms per man hour by 77%.

• Executed power industrial truck and traffic flow study resulting in reduction of equipment and a $92,000 savings.

• Achieved FSSC 22000 (ISO) with no majors marked as “best in plant history” by Dr. Yi Wu, R&D formulator.

Brown’s Dairy Contractor, New Orleans, LA 2016 – 2017 Dairy company divided manufacturing from cold storage and moved operations one year prior to cold storage transition.

Contracted Financial Project Manager

Scope of work included improve of company’s financial performance and plan/direct cold storage relocation.

• Speer headed monthly financial loss through process value stream streaming and financial report analysis. Reduced Over/Under financial loss by $267K monthly in 5 months.

• Improved cold storage yield by $102K per month. Created and implemented Inventory Standard Operating Procedures. Mentored and taught supervisors and leads using Kanban card system and tight inventory controls including visual management and lean methods.

• Created and wrote full project plan and executed transition completing project in corporate’s allotted time. Project scope, plan and execution included hiring labor, operate from two coolers consecutively, purchase equipment, plan satellite delivery / logistics transition, engage and update stakeholders, manage budget, research, select and introduce warehouse management platform and manage handover.

Doug Stuntz

Reddy Ice, Baton Rouge, LA 2013 – 2015 Nation-wide ice manufacturer, producer and sales segregated into regions and markets across the United States.

Market Manager / Director

Hired to create and lead Gulf Coast Market that included Louisiana, Arkansas, Mississippi, and southern Tennessee. The position included leadership and oversight of sales, marketing, safety, logistics (2PL), production and delivery.

Market Transition, Growth and Restructure:

• Led 2013 market creation increase Gulf Coast market profitability after one year in EBITDA by $51K

• Reduced total production cost from 2013 YTD to 2014 YTD by $305K lowering the CPU by $0.16

• Achieved highest grossing market in Mid-South delivering 98% “Service as Scheduled in 2014.

• Member of corporate transition team finalizing sale of market and brokering of ice. Personally closed 4 plants and met with each location including satellite DCs to handout severance packages and assist employees in transition.

Dairy Farmers of America, Schulenburg, TX

2010 – 2012 Top 50 food manufacturer in the U.S. - Frito Lay co packer manufacturing all Frito Lay Dips

Plant Manager

Led unionized plant with over 225 employees and a $30M P&L. Liaison to Frito Lay and responsible for all aspects of the operation.

Market Transition, Growth and Restructure:

• Significantly improved hermetically sealed – retort line efficiency by an increase of 51%.

• Chaired Six Sigma fill height project resulting in annual savings of $250K

• Introduced predictive maintenance; Kanban parts inventory, and satellite maintenance shadow boards

• Designed Food Safety Improvement Plan achieving a 945 AIB (from 745) score and Level I and II SQF certification

• Directed new team safety program focusing on leading edge indicators resulting in a reduction of 10 recordables.

• Designed and implemented team behavioral culture leading to a decertification vote;

ADDITIONAL EXPERIENCE

Food

Plant manager for 10 years orchestrating bottom line grow that the Coca-Cola United flagship plant and awarded McDonald’s Quality award at Chiquita. Overall experience includes cold fill, hot fill, high speed, retort, pharmaceutical, oils, rice, kettles, frozen food, fresh food and coffee.

Textiles

Safety manager for Sara Lee achieving three years without a lost time accident. Plant Manager and customer liaison for Cintas linen

Electronics

Branch Manager hired to achieve first TL9000 audit. End result was no majors and no minors. Only 2nd time in company history.

OTHER SUBJECT MATTER EXPERT

Computer Skills

SAP, AS400, Advanced Excel & PowerPoint, Microsoft Office, WMS, Footprint, Batch Master

Areas of Expertise

SQF II, USDA, FDA, SMED, Green, Six Sigma Master Black Belt, FSSC 22000, TL9000, Ammonia PSM, Thermal Processing

“Doug works very hard and stays committed to outcomes even in the face of adversity. Doug’s continued commitment reinforces his passion and enthusiasm for his role as a leader. Doug’s talents are always evident in his performance. He displays strong leadership abilities, logical thinking abilities, and the ability to work well with teams. He consistently completes tasks accurately and promptly.”

- Courtney Nuttall, HR Manager Reddy Ice

“In recognition of exceptional commitment to quality and customer service, employees at Dairy Farmers of America’s Schulenburg, Texas, facility have been awarded the PepsiCo North American Foods 2012 Service Award for Contract Manufacturing. The award recognizes the Schulenburg team as leaders among 41 contract manufacturing suppliers at 63 locations across the country.” – As Plant Manager, Doug Stuntz master minded a great plan with and mentored a synergistic team per DFA Magazine 2012

“Doug had provided a path to turn three of the six locations from negative to positive EBITDA for the 2015 Fiscal Year. In addition to Doug’s financial aptitude, under Doug’s leadership, Baton Rouge had an outstanding safety record as measured by frequency of accidents and financial impact. In addition to a sound safety record, audit compliance was exemplary at each location.” – Mike Jinks, RVP Reddy Ice

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