Manager Manufacturing

Richard H. Sears

Greater Atlanta Area 404-***-**** *************@*****.*** www.linkedin.com/in/searsrichardh

Manufacturing Manager / Lean Operations Leader

A dedicated, hard-working, honest, principled manufacturing leader who creates team atmospheres, with all levels, for

everyone’s success. An extensive background in manufacturing with experience in operations management, engineering,

and Lean manufacturing principles. Core competencies include:

Operations leadership. Known as an intuitive problem solver with an innate ability to develop the respect and

support of subordinates, peers and other levels of management. At NACOM, reduced employee turnover from 7% to

less than 0.125% per year. Improved overall, indirect headcount by 47% (45 to 24). Reduced safety incidents

(recordable, lost time injuries at SEWS) from an average of two per year to only one in the past three years.

Process improvement. Created process improvement activities at Zenith, NEC, NACOM, and SEWS through

the implementation of Lean manufacturing principles, Toyota Production Systems (TPS), 5S, JIT, Kaizen, Six Sigma,

and zero defect activities. Achieved 94% improvement in quality from 14K ppm to less than 750 ppm. Eliminated

nine work centers which increased available floor space by 7K SF. Improved overall customer, on-time delivery by

16% (from 80 to 96%). Increased machine Operating Equipment Efficiency (OEE) by 20%, from 65% to 85%.

Plant management. Improved overall P&L of operations at NEC, NACOM, and SEWS. Reduced controllable

expenses from $2M per month to break even $500K per month (NACOM). Reduced inventory variance from $270K

to less than $1K (overall inventory of $6.1M, over $4M was electronics at NACOM). Saved $185K transfer of $50M

materials and $1.5M of equipment (NEC). Combined three facilities into one, which resulted in a savings of $5M

(NEC). At SEWS, set record reduction levels for scrap (less than $15K per month average at Sumitomo) for last five

years while supporting the increase of sales from $170M to $185M; accomplished in spite of economic downturn and

Japanese tsunami.

Professional Experience

July 2007 – July 2013 SEWS Edmonton, Kentucky

A subsidiary of Sumitomo Wiring Systems International, SEWS is a $185M manufacturer of automotive electronics with

300 employees. Certified TS 16949 and ISO 14000. Products shipped worldwide.

Manufacturing Manager, Electronics Division

Responsible for all aspects of a three shift manufacturing operation that produces electronic components and sub-

assemblies. In charge of six direct reports and up to 250 indirect with support group responsibility on off-shifts.

Improved production efficiency by 9% from 82 to 91%.

Recertified facility for TS16949 registration with no majors or minors for four successive years.

Reduced direct expenses by average of $11K per month and maintained continued reductions since 12/07.

Based on international Japanese review, scored highest ever on production / 6S audit (89 versus 79).

Coordinated level loading of 2008 Accord product to reduce OT and improve efficiency by 7%.

Initiated improvements in all major areas of business, Quality 40%, IPD 15%, Scrap 25% (set 5 year record).

Implemented revised 5S system for factory on all shifts.

Supported overall business improvements through TPS responsibility for the Plant within the last three years.

Built out five model families, started up seven new product families, and two new SMT lines (including NXT

system).

Supported budget reduction of 10%, with a 15% reduction for direct expenses.

Oversaw the restructuring of an Access database from Excel for improved, consistent, and accurate reporting.

Reduced direct headcount by 20%, through model build outs and efficiency improvements.

Conducted major sort activity for Japanese base part for six months to support quality improvement activity.

In addition to normal duties, served as interim materials manager for a six-month transitional period.

Richard H. Sears Page 2

2000 – 2006 NACOM Corporation Griffin, Georgia

Part of Yazaki North America, NACOM was a $115M manufacturer of automotive electronics with 400 employees.

Certified QS9000, TS16949, and ISO14000. Products shipped throughout U.S., Mexico, Asia, and Europe.

Plant Manager, Electronics Manufacturing

Responsible for all aspects of a three-shift manufacturing operation that produces electronic components and sub-

assemblies. In charge of seven direct reports and up to 300 indirect. Employed "Focus Factory" concept.

Reduced controllable expenses (P&L) from $2M to $500K per month. Scrap from $250K to less than $15K.

Reduced hourly personnel turnover per year by 7% (350 headcount), to less than 0.125%.

Improved indirect headcount by 47%, (45 to 24).

Decreased accidents (OSHA recordable, lost time injury) from two per year to one incident in the final two years.

Improved productivity 30%, which allowed elimination of third shift.

Achieved quality improvement from an initial 14K ppm level to less than 750 ppm level (94%).

Increased monthly delivery average by 16% (80% to 96%) including introduction of over 200 new models.

Improved semi-annual inventory variance from $270K to less than $1K (overall inventory $6.1M, EMD $4M)

Increased machine Operating Equipment Efficiency (OEE) 20% (65% to 85%).

Supported implementation of a Reliability Centered Maintenance program utilizing Datastream 7i Asset Management

System; supported 850 pieces of equipment and an inventory of 10K spare parts at cost of $1.3M.

Implemented Lean manufacturing principles, 5S, Toyota Production System (TPS) methodology, zero defect

activities, Six Sigma metrics, and began flexible line concept. Nine less work centers creating 7K+ SF.

Provided operational guidance for development and implementation of ISO14001 environmental management system

(EMS), QS9000, and site certification for TS16949.

1990 – 1999 NEC Technologies McDonough, Georgia

Part of NEC International, NEC Technologies is a $100M manufacturer of computers and computer peripherals with over

400 employees. Certified QS9000, and ISO14000. Products shipped throughout U.S., Mexico, and Asia.

Director of Operations, Director of Manufacturing, Engineering Management

In charge of a tri-plant site, including accounting, distribution, engineering, facilities, human resources,

manufacturing, materials planning, purchasing, inventory control, MIS, product recovery operation and quality.

Chosen for site selection committee of a new Mexican operation for manufacturing product.

Combined three facilities into one, prepared excess buildings / property (100 acre site) for resale; saved $5M.

Implemented Lean manufacturing principles and Toyota Production System (TPS) methodology.

Managed operational and support groups to attain scheduling and material transfer of product two weeks ahead of

schedule. Saved $185K transfer of $50M materials and $1.5M of equipment.

Key local player on real estate review committee, enhancing value from $45K to $115Kper acre due to rezoning.

Led marketing and manufacturing teams for facility selection as first overseas site for worldwide manufactured

product line of 21’’ monitors. Gained overall savings of $50 per unit and $3M in materials.

Performed intense industrial engineering review of manufacturing, saved $250K. Modified plants based on work

cells, KanBan and just in time (JIT) methodology.

Education and Professional Development

Currently enrolled in bachelor of science program at Reengineering Principles from Clayton State

Colorado Tech Lean Manufacturing Concepts (IE Communications)

Dale Carnegie course in Human Relations

Toyota Production System (TPS)

Richard H. Sears Page 3

Shainin Apprentice Problem Solving

Contact this candidate