Manager Continuous Improvement

Rodney Ady

*** ******* **. **

Navarre, Ohio ****2

Phone: 330-***-****

e-mail: *********@*****.***

Data driven hands on leader with a team oriented approach to continuous

improvement, and ten years of successful production, planning, and

logistics management. Proven track record of leading teams and projects

that resulted in multi million dollar savings in revenue and profits,

through double digit improvements in throughput, production yield, and

successful Lean Mfg projects. Extensive experience in the manufacturing of

specialty steel and wire through cold rolling, cold drawing, thermal

processing and hot dip coating Responsible for the safety, quality, and

productivity of 160 non union employees. Focused areas of success and

experience include:

. Safety Behavior Management . Waste Reduction

. Continuous Improvement / Lean / SMED / TPS . Inventory

Management, Kanban

. 6S Implementation . ISO: 9001-2000 Quality Systems / TQM

. Kaizen/Quick Set-up and Change Over . Operations Metrics,

8D Analysis, PDCA

. Staff Planning . Six Sigma Tools, DMAIC/SCRA/5 Why

. Customer Focus/VOC/Internal/External . ERP SAP System

PROFESSIONAL EXPERIENCE

Bekaert Corporation Sept 2010 - Present

Lead production groups including team leaders to drive change within the

organization in regards to safety, quality, and productivity . Responsible

for daily production output, staffing, overtime, and cost reductions.

Report KPI's and promote mini company concepts for a motivated and

empowered workforce.

Production Manager

. Developed and implement a Kanban ordering system to reduce inventory

and overproduction.

. Built a team with a collaborative focus on uptime and machine

reliability to improve delivery performance and address bottle neck

situation.

. Developed an operational metric with involvement of SAP competence

center to generate production reports out of SAP to report operator and

machine efficiencies as well as an OEE measurement.

. Introduced 5S standards via visuals to progress 5S to the next level

and take subjectivity out of the audit process..

. Implemented daily board meeting to discuss safety, quality, and

productivity to involve, empower and promote employee engagement.

Glass house concept.

. Reduced set up time by 65% on a cold rolling mill by conducting a

Kaizen event with a cross functional team resulting $1,080,000 increase

in revenue.

. Implemented man machine model to reduce labor cost by $150,000

annually.

. Researched and justified the implementation of downtime data collection

machines to provide pareto analysis of downtimes reason codes resulting

in a 10 to 15% production increase.

Bekaert Corporation

Jul 2006 - Aug 2010

Promoted from Production Manager to Operations Manager responsible for all

production in 3 plant location, planning, shipping and receiving in an

organization that operators twenty four hours a day seven days a week.

Position had 13 direct reports and 150 hourly employees. Still responsible

for leading lean activities and continuous improvement events.

Operation Manager

. Reorganize shipping floor for better product flow to the shipping

resulting in a 35% reduction in material picking and loading.

. Created a matrix of customers that could be combined on trucks to

reduce shipping cost with an annual savings of $24,000.

. Created shipping bins within SAP with bar codes for rack systems

resulting in better inventory management.

. Implemented pull system using kanban carts to regulate inventories from

rolling to heat treating with a reduction in WIP of 60%.

. Conduct internal VOC exercises to improve employee relationships and

establish standards that will better satisfy internal customers

resulting in improved quality and productivity.

. Responsible for freight cost including expedited freight and detention

fees.

. Reduced OT by 40% through cross training and weekly staffing reviews

with team leaders and planning department.

. Responsible for determining annual capital projects along with cost.

Bekaert Corporation

Feb 2003 - June 2006

Production Manager

Promoted from within from CI to Production Manager, responsible for

production and implementation of continuous improvement activities though

investing in people systems and facilities. The main focus was getting

team leaders to start focusing more on continuous improvement through

training, coaching, and mentoring.

. Train Team Leaders to become more data driven and approach the floor

with a purpose.

. Lead several kaizen events with the help of team leaders.

. Implemented lean culture in a custom manufacturing operation and

championed team efforts of waste elimination using lean and six sigma

techniques such as value stream mapping, visual factory, Kanban's, 5S,

statistical control and customer-supplier relationships.

. Reduced scrap on heat treating line by 40% by creating a continuous

run process that was no nonsense and cost affective resulting in nearly

$100,000 annual saving.

Bekaert Corporation Nov 1999 -

Jan 2003

Promoted from production laborer to Continuous Improvement Coordinator with

the responsibility of improving processes through lean tools and problem

solving methodologies including but not limited to DMAIC, SCRA, 5 Why,

Is/Is Not etc.. reporting to senior management every two weeks on corporate

objectives.

Continuous Improvement Coordinator

. Reduced labor cost on Punch Press process by 50% which was a cost

saving of $90,000 annually. .

. Implemented 5S on several work center to improve safety, housekeeping,

and productivity.

. Increase Punch Press productivity by 200% by replacing air feed

gripper system with servo feed roll system.

. Increased throughput on Pickle Process using process mapping to

increase value added activities. A cost savings of $300,000 annually

in outside processing.

. Champion of several successful Kaizen events to reduce set up and

change over time on bottle neck work centers. The best one resulted in

80% reduction in set up time resulting in $900,000 annual increase in

sales revenue.

Bekaert Corporation

Nov 1994 - Oct 1999

Production Laborer

. Assistant Operator on Straight and Cut Line.

. Rolling Mill Operator .

. Drawer Operator.

. Exact Length Operator.

EDUCATION

. Stark State College: Associate of Applied Science in Industrial

Engineering Technology

Certificate in AutoCAD

. University of Phoenix: Bachelor of Business and Supply Chain

Management expected

completion in December 2013

Professional Development

. Various Lean Manufacturing Certificates

. Certified internal ISO 9001 Lead Auditor

. Owner Operator of Bounce Barn Inflatable Rentals

. Commissioner of Fairless Midget Football (Flag Football)

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