Manager Plant

Jerry Estes

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Home: (717) 818 - 5853 : J *********@***.***

Summary

Results-driven, skilled Production Manager focused on achieving success and increased productivity, by leading

high-producing teams and using lean manufacturing.

Highlights

Experienced in production scheduling Team building

Knowledgeable of quality standards Cost reduction and containment

Lean manufacturing and design Troubleshooting and problem solving

Accomplishments

Cut overall costs by adding full time associates to handle vacations and decrease overtime

Managed several processing projects to make new products that were completed by working with R & D and contractors

Improved quality by improving process cleaning circuits with PLC programming changes

Lean Manufacturing and Lean Management certifications in 2009-10

SQF Practitioner in 2012 and integral leader in obtaining excellent ratings in four different SQF audits

Experience

Plant Operations Manager

January 2012 to November 2013

Dairy Farmers of America - Mechanicsburg, PA

Change Management: Responsible for changes to bring the plant from a 4 day work week to a schedule that

regularly scheduled 6 and 7 day work weeks within a year.

Revamped supervision to manage the plant across all three shifts over 7 days.

Developed levels in job descriptions to recognize differences in job positions and to cover vacations and days off

without using overtime.

Production Volume: The plant set records in volume over two years and is the lowest cost plant in the group of

plants across the country

Streamlined the processing and filling departments to improve sanitation and to optimize the blending of

Starbucks Frappuccino and Iced Coffee to keep pace with packaging

Management: The Mechanicsburg plant is the biggest producer of Starbucks Frappuccino and the only producer

of Starbucks Iced Coffee.

Managed 6 supervisors with 80 employees that produce over 25 million dozens of Starbucks coffee with milk

beverages a year.

Quality: The plant achieved Excellent scores on two SQF audits Level Three

Plant Production Manager

January 2005 to December 2011

Turkey Hill Dairy, The Kroger Company - Conestoga, PA

The plant produced over 25 million gallons of ice cream and over 50 million gallons of milk and tea beverages a

year.

Management: Managed the frozen production, fluid production and the processing departments that incorporated

over 170 associates across three shifts that flexed between 5 and 7 day work weeks.

Quality: All production personnel were trained in Lean Manufacturing in 2009 and 2010.

Many continuous improvement projects were completed and saved the company thousands of dollars over four

years.

The mindset and culture change in Lean thinking was challenging, but invigorating.

Lean Manufacturing: Led a team to maximize production speed with no let down in safety and quality to lower

overtime.

A three month project from one department netted the company over $300,000 in savings of overtime.

Employee morale was also improved by freeing up more weekend time for associates.

Frozen Production Manager

January 1997 to January 2005

Turkey Hill Dairy - Conestoga, PA

Management: Mentored many associates to ready them to be team leaders and supervisors and managers

across the company.

Machinery Upgrades: Wrote the ROI on upgrading all ice cream lines to more efficient equipment and adding

the best group of HTST units and tanks.

Quality and Safety: Many valves, process lines and fillers were upgraded to be more efficient.

Process Improvements: Redesigned a production line to bundle ice cream pints with shrinkwrap only without

using trays and taking out a person to pack them.

Production Supervisor

November 1990 to January 1997

Turkey Hill Dairy, The Kroger Co. - Conestoga, PA

Plant supervision: Converted the second shift of the frozen and fluid production departments from sanitation only

to production.

Sanitation was moved to all operators on all shifts when it was required.

Sanitation: Updated most systems to PLC based systems and validated CIP circuits visually with the code.

Production Planning: Helped develop a JIT scheduling system for ice cream production and then fluid production.

Raw ingredients, packaging were planned for one day at a time for a rolling two week period.

Warehouses were not expanded for consistent growth in volume.

E ducation

Master of Business Administration : Management, 2011

Southeast Missouri State University - Cape Girardeau, M O

Bachelor of Science : Management, 1985

Southeast Missouri State University - Cape Girardeau, MO

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