Manager Project
Resume:
OPERATIONS LEADERSHIP / LEAN TRANSFORMATION EXPERT
LEADERSHIP _ TEAM BUILDING _ PROBLEM SOLVING _ SPEED _ RESULTS
Bob Bex
Denver, IN 46926
*****@***.***
PROFESSIONAL SUMMARY
As a leading expert in manufacturing start-ups, turnarounds, and day-to-day operations, my entire career has been branded around the
relentless pursuit of perfection utilizing Lean / Six Sigma / Project Management strategies / Organizational Design (OD). As one of the first
18 original people selected, I began the “lean journey” in 1992 when General Motors created the Quality Network as the launch vehicle for
what was then termed, "Synchronous Manufacturing."
Having facilitated and led over 250 Kaizen events, coupled with extensive program / project management experience, I have successfully
created a unique and effective methodology to analyze the voice-of-the-process, identify causals, and rapidly implement counter-measures.
The companies I have represented considered me a strong leader and a premier change-agent and developer of people and teams, based
on 20 years of diverse experience and successful results. The following outputs are directly attributed from inputs as stated, within:
• Successfully launched +220M new product line and initiated the first union / management team empowered to jointly develop all
related processes (General Motors)
• Transformed VOC performance of an major aerospace OEM from the “wall of shame” to “Supplier of the Year” in <18 months
• Led an organization-wide turnaround for a $50M S-Corp from near bankruptcy to Chamber of Commerce “Business of the Year” in
<30 months
• Championed new “Greenfield” manufacturing (foundry) start-up, including IRB (Industrial Revenue Bond) financing, building
construction, equipment procurement & installation, organizational design, and production launch.
• Successfully transformed a $50M mixed-model facility (300K sq. ft.) from100% batch / queue to 100% takt/flow/pull in <12 months
• Recently championed the largest flow transformation project in the history of a $225M low-volume/mixed-model aerospace OEM,
including 147 unique part numbers on takt/flow/pull that accounted for 81% of total volume
VALUE PROMISE:
High-performing leader with relentless passion towards obtaining results; supportive advocate of executive team to improve profitability;
passionate leader convinced that advancing and institutionalizing Lean Enterprise will solidify market competitiveness; decisions
predominately based on objective data and related key performance metrics; strongly convinced and driven to continually build / coach /
mentor teams to empower decision-making in order to solve problems from and advance ownership / accountability
LEADERSHIP BRAND:
Self-motivated, collaborative, empowering and trusting. Known for developing strong relationships with team members and customers,
raising the bar to higher expectations and achieving “stretch” goals; creating a culture that invites creativity with emphasis on speed and
“doing it right the first time”
AREAS OF EXPERTISE:
Project / Program Management New Product Development / Launch Work Breakdown Structure (WBS)
Complex Negotiations & Deal Structuring Strategic & Tactical Planning Business Development & Market Expansion
“Greenfield” Development & Start-up Process Mapping & Re-engineering Turnaround Management
Lean / Sigma Implementation Policy / Goal Deployment DMAIC (Problem Solving)
Design / Process FMEA P&L/Fiscal Management Asset Management / Depreciation
Activity Based Costing Team Building & Training Work Instruction Development
MFG Linkage / Flow / Line Balancing Supplier Development Star Analysis (Organizational Design)
CERTIFICATIONS & TECHNOLOGY SUMMARY:
Design for Six Sigma Train-the-Trainer Six Sigma Black Belt for Leadership Lean/Sigma Green Belt
Lean Expert ISO 9000 Lead Auditor Gear Machining Metrology
Qualified A3 trainer PM Software (Primavera / M-Project) Vantage / JDE
PERSONAL BIO:
Pursuant to serving 4 years in the United State Navy as a member of the underwater ops Team, ‘walked-on’ and earned a full athletic
(football) scholarship at Ball State University. As a student, excelled in the classroom and completed undergraduate degree in Business
Administration in 2.5 years; played final football season as a graduate student; awarded BSU football “Student Athlete of the Year; selected
twice to the Mid-American Conference Academic 1st Team; and selected once to ESPN’s Academic All-Region 1st Team.
Earned a M.S. in Business from Central Michigan University with a published Thesis, “Implementing Lean MFG. & Single Piece Flow.”
MILITARY EXPERIENCE:
United States Navy – Underwater Ops Team/Spec OPs -- 1982 to 1986
OPERATIONS LEADERSHIP / LEAN TRANSFORMATION EXPERT
LEADERSHIP _ TEAM BUILDING _ PROBLEM SOLVING _ SPEED _ RESULTS
PROFESSIONAL EXERIENCE:
FULTON INDUSTRIES (South Bend IN)
Machining manufacture of large grey iron (ductile) engine components (Family Owned Business)
Director of Operations, 4/2013-current
Recruited to implement multi-site Lean Operating System, as well as, expedite customer diversification strategy to mitigate risk.
• Long-term relationship with ownership ; whereas, I was asked to lead turnaround efforts with emphasis on mitigating risks associated
with a single customer (major OEM) representing 95% of total business ($52M total revenue / 3 manf Sites)
• Developed 5 year STRAP, identified & developed plans around top 3 business and operational priorities, as well as, performed current
state organizational design (OD) gap analysis (STAR Model – Strategy, Systems & Processes, Metrics & Rewards, Human Talent,
Organizational Structure)
**Informed 11/2013 by single largest OEM customer that 80% of current demand has been dual sourced (low-cost country), resulting in
imminent RIF & plant shutdown **
HONEYWELL AEROSPACE (Urbana, OH)
Designer and manufacturer of commercial & military aircraft lighting
Multi-Plant Site Leader (Honeywell Operating System), 6/2012 to 4/2013
Former manager reached-out & hired me (3rd occurrence) with expressed emphasis on improving the multi-site Operating System, as well
as, serve as multi-site champion for the lean transformation project
Selected Achievement Highlights:
• Successfully transformed the entire Circuit Card Assembly (CCA) work-center from 100% batch/queue to takt/flow/pull consisting of
three product families totally 147 part numbers (54%) comprising 81% of total volume
• Led all efforts at two (2) sites in the assessment, gap analysis, and countermeasure development to regain Honeywell Operating
System Bronze Certification
TIMCO AEROSYSTEMS (Greensboro, NC)
Designer and manufacturer of cabin interior products for commercial passenger aircraft
Commercial Aircraft Seating Start-up Leader / Project Manager, 7/2010 to 7/2011
Recruited to lead start-up of NC commercial aircraft seating operation, including world-class low volume / mixed model Lean “Flow-line.”
Selected Achievement Highlights:
• Successfully planned & executed “greenfield” startup of a new product business unit, including FAA certification
B/E AEROSPACE (Winston Salem, NC)
Designer and manufacturer of seating for commercial passenger aircraft
Program Management Office (PMO) Director / Senior Program Manager, 1/2008 to 7/2010
Recruited by former Manager from Honeywell to help build a PMO (Project Management Office)
Selected Achievement Highlights:
• Utilized Lean/Six Sigma methodologies in the development and launch of the Project Management Office (PMO). Led team(s) in
developing / implementing accurate financial statements, key business metrics, and robust New Product Introduction (NPI) process
with phase gates assess progress
• Reversed losses into profits, serving as the catalyst for $2.8M new business based on an upgrade solution for a major airline
• Served as Program Manager responsible for $220M P&L, representing largest single account within business unit
G&S METALS, Inc. (Wabash, IN)
Privately-held S-Corp aluminum foundry, producing aluminum ingot for the production of automotive wheels, & structural components
Vice President of Operations, 1/2003 to 12/2007
Recruited to lead turnaround and position Company for growth to become a multi-plant operation
Selected Achievement Highlights:
• Realized +300% productivity, +80% EBITDA improvement, and 6x revenue growth in less than 2.5 years, resulting in release of
owner’s personal guarantees (PGs) with the bank and 2007 Chamber of Commerce Business of the Year
• Developed business plan for domestic growth strategy and secured IRB financing for new 53,000 sq. ft. manufacturing facility in
Georgia. Championed & led development, construction, and start-up of new Greenfield Facility, resulting in +35% revenue growth
HONEYWELL AEROSPACE (Rocky Mount, NC)
Major OEM Supplier of aircraft engine (hydro mechanical) controls
Product Launch Manager / Senior Program Manager, 5/2000 to 8/2002
Challenged to take over largest revenue producing, but worst customer performing, product line with full P&L responsibility of $85M.
Selected Achievement Highlights:
• Transformed the poorest performing program into a top-performer through lean business/process implementation, reducing process
variation, and “roll-up-the-sleeves” hands-on approach. Sustained improvements led to the “Eagle of Excellence” Award for top supplier
and produced follow-on contract worth $1B NPV to supply fuel controls for JSF war fighter
TUTHILL TRANSFER SYSTEMS (Fort Wayne, Indiana)
OEM manufacturer of fluid transfer pumps
Plant Manager, 4/1999 to 5/2000
Recruited to manage all operational functions with emphasis on leading Lean transformation
Selected Achievement Highlights:
• Created flow through direct linkage of machining and assembly, eliminating WIP and capturing 60% cycle-time reduction
• Improved on-time delivery by 35% and realized a 60% reduction in setup / change-over cycle-times through SMED events
Early career included Quality Engineer/Program Manager for Nucor Bearing Products. Wilson, NC (1997 to 1999), and Quality Network
Manager/New Product Launch Manager for General Motors (New Venture Gear), Muncie, IN (1991 to 1996)
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