Manager Manufacturing

H. DOUGLAS SHIREY **** Meadow Ridge Court ~ Dexter, MI 48130

734-***-**** Home ~ 734-***-**** Cell

***********@*****.*** ~ Linkedin.com/in/dougshirey

VICE PRESIDENT OF MANUFACTURING / GENERAL MANAGER

DIRECTOR OF MANUFACTURING

Strong Breadth and Depth of Experience to Achieve Peak Performance in any Organization

Results-proven Senior Manufacturing Executive with extensive experience leading and directing multiple

manufacturing operations/facilities with in depth knowledge of strategic/operations business planning, acquisitions,

and start-ups . Strategist and leader with a track record of improving profitability through aggressive budgeting and

cost management.

A profit-focused manager specializing in cultivating, implementing and sustaining high performance cultures through

application of lean manufacturing methodologies and flawless execution tactics who leads by example, and

equips/empowers staff to set and consistently exceed stretch goals and objectives. Known for being energetic,

versatile, decisive, and confident.

CAREER HIGHLIGHTS

THETFORD CORP. / NORCOLD INC. - Ann Arbor, MI 2001-2013

(The world's leading manufacturer of mobile sanitation products for the RV, marine, camping, and truck markets with

$150M in annual sales)

DIRECTOR OF MANUFACTURING, NORTH AMERICA (2007-2013)

Directed the RV sanitation and refrigeration manufacturing operations for 4 North America manufacturing

facilities (Ann Arbor, MI; Dexter, MI; Sidney, OH; and Gettysburg, OH). Managed/led 9 direct reports and

accountable for Plant Managers, Manufacturing Operations, Quality, Materials, Distribution, Manufacturing

Engineering, Maintenance, and Environmental Health & Safety. Indirect responsibility for 45 salaried and 500

non-union hourly employees with an annual budget of $30M.

Created and promoted a “high performance” culture by establishing ambitious goals for all manufacturing

locations and setting expectations for on-time and complete commitments.

Implemented and enhanced lean manufacturing at all locations with the Dexter facility being recognized as

a “best in class” application of lean methods by the University of Michigan Ross School Of Business.

Directed annual continuous improvement and cost reduction programs for all facilities with consistent

achievement of targeted savings of $300K annually.

Led in-sourcing projects as a Business Leader that brought in-house the manufacture of 2 major product

lines. Both projects resulted in a 15% increase in profit margins and increased speed to market,

Launched production of 3 major refrigeration and 3 major sanitation products for global markets that

quickly addressed changing market conditions and increased competitive pressures.

PLANT MANAGER, SANITATION DIVISION (2001-2007)

Responsible for the manufacturing operations consisting of the assembly of sanitation systems, liquid chemical

manufacture and packaging for 2 Sanitation Division facilities leading 7 direct reports, and 15 salaried/125 non-

union hourly indirect reports. Managed an annual budget of $12M directing the Manufacturing Operations,

Quality, Materials, Distribution, Manufacturing Engineering, Maintenance, and Environmental Health & Safety

departments. Advocate of lean manufacturing and driven for best-in-class performance goals and objectives.

Launched and championed a behavior based safety program that resulted in a 70% reduction in

recordable injuries in 1st year.

Implemented and refined Toyota Production System of pulling production from vendor parts, through

production to on-time customer delivery.

Achieved 7 consecutive years of increased inventory turns.

Consistently achieved greater than 98% on-time shipments to multiple market segments including

OEMs, mass merchandisers and distributors.

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H. DOUGLAS SHIREY Page 2

Developed “vital few” key performance indicators and performance dashboard that drove continuous

improvement throughout manufacturing operations reducing matrix from 140 to 15.

Led manufacturing team through the acquisition of 3 different businesses and integration of production into

existing facilities.

Launched 7 new sanitation products and systems over a 3-year period of growth resulting in no loss of

market share, and maintaining the company as a market leader during the recessionary period.

Initiated/oversaw large capital equipment and facilities upgrades of $3M such as purchasing liquid

mixing/bottling and dry chemical blending equipment, a new roof, and HVAC equipment.

SCHRADER-BRIDGEPORT INTERNATIONAL, INC.- Altavista, VA 1997-2001

(A global leader in the design and manufacture of valve, mechanical, and electronic system components and

sensing technologies)

Plant Manager / Monroe, NC (2000-2001)

Full P&L responsibility for a high volume machining and assembly plant that supplied various tire hardware and

components to the automotive industry and aftermarkets. Managed/led a staff of 150 salaried and non-union

employees.

Managed a turn-around of $35M Tier 1 automotive business that was targeted for closure into a profitable

operation postured for future growth.

Launched and championed 5 six sigma “black belt” projects with 1st year savings of $600K.

Won 2 major contracts ($2.5M) with previously untouchable market segments.

Plant Manager / Altavista, VA (1997-2000)

Directed all aspects of operations including full P&L responsibility for high volume machining and assembly plant

that supplied air conditioning valves and fuel system valves and components for the automotive industry and

aftermarkets. Led a staff of 200 employees.

Led integration of the manufacture and assembly operations from an acquisition of do-it-yourself pressure

washers and air compressor product lines into existing operations in 1-week.

Supported automotive air conditioning components business growth of 30% to $70M through creative

staffing solutions and “re-engineering” assembly processes.

Implemented lean manufacturing techniques which resulted in a 15% reduction in labor/operating costs.

Led the plant in achieving ISO90001/QS9000 certifications.

Awarded NAPA “Manufacturer of the Year” Award for 2 product lines - a NAPA first.

AMCAST AUTOMOTIVE - Franklin, IN 1996-1997

(A manufacturer of aluminum wheels for automobiles and light trucks, and squeeze-cast aluminum casting used

with automobile suspensions and brake systems)

Director of Manufacturing

Launched 2 greenfield casting facilities (Franklin, IN and Wapakotna, OH) with state of the art processes for the

manufacture of automotive suspension components. Activities included an acquisition, installation of equipment,

and hiring of salaried/hourly personnel.

Developed a 7 day/4 shift operation that maximized return on large capital investment.

FORD MOTOR COMPANY - Dearborn, MI 1990-1996

Manager, Supplier Technical Assistance (1994-1996)

Lead and directed staff of 8 professional engineers that supported corporate/division cost and quality

expectations with supply base.

Implemented/managed several supply base improvement initiatives focusing on cost reductions and quality

improvements with over 250 Tier 1 suppliers to Climate Control Division.

Exceeded 1st year goal of 50% reduction in supply base quality and delivery concerns.

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H. DOUGLAS SHIREY Page 3

Manufacturing Superintendent, Evaporator-Radiator (1992-1994)

Managed a multi-shift production operation of union employees in fabricating automotive radiators and

evaporators.

Turned around 2nd and 3rd shift operations from historically missing schedules and exceeding spending

budgets to achieving “best in plant” recognition.

Supplier Quality Engineer (1990-1992)

Qualified and developed suppliers to Ford Motor Company Climate Control Division facilities.

First to apply and implement Ford Quality System standards for purchased parts across raw material

supply base with 85% success rate in 1st year.

MILITARY SERVICE

UNITED STATES AIR FORCE (Honorable Discharged) 1977-1980 & 1982-1990

Commissioned Officer

Captain - Procurement Officer (1985-1990)

Manufacturing Manager for final assembly and check-out of a large aircraft procurement program.

Developed work measurement standards and cost metrics for a high cost/low volume production operation

with contracts totaling $500M.

Non-Commissioned Officer

Engineering Supervisor (1982-1985)

Supervised engineering support for military construction programs.

Completed $1M in construction programs in one fiscal year - a record for Travis Air Force Base.

EDUCATION / PROFESSIONAL DEVELOPMENT

Master of Science Business, Contracting Management

Air Force Institute of Technology - Dayton, OH

Bachelor of Science, Industrial Technology

Southern Illinois University - Carbondale, IL

Continuing Professional Development: University of Michigan, Japan Technology Center Lean Manufacturing

Annual conferences - 2001 through 2005; University of Michigan Ross School of Business Lean Manufacturing

Executive Seminars 2008 through 2010.

Attended company sponsored training programs in: Strategic Sourcing and Procurement; Kepner-Trego

Problem Solving and Decision Making; Flawless Execution Principles and Methodology; Lean/Six Sigma

Program Champion; Best in Class Quality Systems; and Quickchangeover.

TECHNICAL SKILLS

Proficient in the use of PC and mainframe software programs: MS Windows, Word, Excel, Powerpoint, and

Project.

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