Plant / Operations Management

Allan W. Kerns

**** ***** **** ***** *. Woodstock, Georgia 30189 770-***-**** ******@*******.***

Manufacturing / Plant / Operations Manager

Results-driven, top-performing management professional with comprehensive experience improving operational efficiencies, reducing expenses, driving ISO / TS compliance, and cultivating solid client relationships. Proven success in turnaround situations driving profitability through key actions in operations reorganization. Recruits, trains, and coaches teams to exceed plant metrics through ongoing needs assessment and increasing accountability. Expert relationship manager with the ability to establish trust, deliver value, and create long-term relationships with customers, manufacturers, and distributor networks. Additional skills include:

* P&L Management

* Estimating & Sales

* Lean Manufacturing

* Strategic Planning

* Process Engineering

* Just-In-Time Manufacturing

* Budgeting / Forecasting

* Metrics & Measurements

* Teambuilding & Leadership

Professional Experience

Torco, Inc., Marietta, Georgia

* Mazak Multiplex CNC Horizontal Lathes / Mazak Vertical Machining Centers / Acme & New Britain Automatic Screw Machines / Cincinnati Centerless Grinders / Broaching / Various Secondary Operations.

General Manager Feb 2012 - Current

Position includes leading the company of 60 employees with a staff of 6 indirect employees. With Torco being a smaller company I find myself being more involved with the daily agenda on the shop floor. My responsibilities include Sales, Quoting, P&L, Budget, Engineering and Strategic Planning. My staff includes a Plant Manager, Quality Manager, Engineering Manager and an Office Staff of four. We hold Quality Certifications such as ISO 9001 / TS-16949 and will be AS9100 Certified by June 2014. Torco is considered a Job Shop serving such industries as the Automotive, Agriculture, Aerospace and commercial segments of manufacturing. I have worked diligently to rebuild customer relationships as well as having the ability to gain new customers and a significant amount of sales in a short period of time.

Key Contributions:

* Introduced and implemented Lean Manufacturing Concepts into the plant and workforce.

* Established employee involvement by the use of monthly Roundtable meetings.

* Developed employee of the month and year with incentives.

* Reduced inventory levels throughout the company by $450K during the first year.

* Developed Pay for Performance Evaluations for all employees within the plant.

* Created monthly budgets for all managers to follow and had them report out at weekly staff meeting.

* Maintained 100% On-time delivery each month with 0 customer PPM.

* Developed and implemented training program for machine operators which included Safety, Quality and Machine Operation as well as Tool Setting.

United Brokers Group, Chandler, Arizona

Realtor® Jan 2011 – Jan 2012

Self-employed residential sales agent for one of the top 3 real estate companies in Arizona. Created my own business starting with my goals, budget and business plan. Developed and negotiated contracts between buyers, sellers and banks. Spend most of my time building customer relationships and communicating with clients.

Whirlaway Corporation, Tempe, Arizona (Company closed due to consolidation).

* Swiss CNC, single and multi-spindle (Acme, Tornos and Schutte) screw machine manufacturing supplier to Tier 1 automotive industry throughout the world.

Operations Manager Jul 2006 – Sep 2010

Duties included directing and leading a staff of 20 indirect members and as many as 175 direct hourly employees. At times I had to perform the position of Material Manager, Production Manager when needed while continuing with Operations. Worked hand in hand with customers to build and maintain strong business relationships. Helped to resolve tooling, setup, material and quality issues as well as operator problems on the shop floor. Lead strategic planning throughout with P&L and budget responsibility for the company.

Allan W. Kerns

1064 Towne Lake Hills E. Woodstock, Georgia 30189 770-***-**** ******@*******.***

Key Contributions:

* Reduced the cost of doing business by over $400K per month during economic downturn.

* Established employee involvement by the use of monthly Roundtable & Communication meetings.

* Created employee of the month as well as employee of the year awards.

* Increased efficiency to 96% from 63% through training, planning and employee involvement.

* Formed and implemented with the help of Human Resource, employee evaluation throughout the facility.

* Created monthly budgets for all managers to follow and had them report out at weekly staff meeting.

* On-time delivery increased above 98% from 67% through the efforts of all employees

* Developed a team and completed implementation of Lean Manufacturing concepts into the workforce.

Dayton Superior Corporation, Rushsylvania, Ohio

* CNC, single and multi-spindle (Acme, Brown & Sharpe) screw machine manufacturing company servicing fields such as fluid power industry, construction products, and electrical contact components.

Operations Manager Jan 2003 – Jul 2006

Expectations of my position were to hold full strategic planning, development, and operational responsibility of the plant with 69 employees. Developed and cultivated new business relationships with clients at the same time as maintaining and restoring the current business. Had to rebuild and strengthen relationships with all vendors and intercompany ties. My position required identifying operational issues, implementing long term solutions and developing a sound infrastructure. I held full financial responsibility for the plant including budgetary and P&L duties.

Key Contributions:

* Played an integral role in positioning the organization to achieve ISO certification in 2006.

* We focused on increasing sales $1.8M within 42 months by defining and leading turnaround initiatives, securing new clients, expanding manufacturing capabilities, and solidifying existing account relationships.

* Increased our efficiency to above 90% and labor force by 30%, through efforts identifying emerging business opportunities, diversifying offerings, and enhancing processes to handle more complex projects.

* Dramatically improved customer relations by meeting with all customers within first month of employment, assessing needs, and focusing on open communication and proactive problem resolution.

* Boosted on-time delivery to 97% from 42% eliminating a severe backlog of orders, by facilitating department training, defining performance metrics, and increasing individual and team accountability.

* We developed a team to increase organizational effectiveness by deploying lean manufacturing methods, developing quality control department and standards, and creating a first-time preventative maintenance program.

* Cut the annual operating budget by more than $322,000 through key actions in operations reorganization, turnaround management, expenses control, and efficiency improvement.

Carmichael Machine, Springfield, Ohio

* CNC and Multi Spindle (Acme, New Britain) screw machine manufacturing supplier to lawn and garden, fluid power and agriculture manufacturing companies.

Manufacturing Manager Nov 1999 – Jan 2003

Oversaw plant wide production, scheduling, safety, quality and budgeting with as many as 50 team members. Worked directly with all employees on the floor and answered to Operations Manager. Responsibilities included all hiring and disciplinary action as well as evaluation of all employees.

Key Contributions:

* Oversaw production, scheduling, safety, quality, and budgeting with up to 50 team members.

* Immediately brought in changes by implementation of lean manufacturing processes, a setup reduction program, and new training initiatives.

* Assessed organizational needs, identified gaps and redundancies, and implemented new processes and procedures to secure ISO: 9001 certification; we seen company wide efficiency increase to 92% from 65%, and cut expenses by $110,000 annually from tooling budget.

* Worked with and improved employee attendance 38% from 6.23 to 3.86 absences per employee in 2001.

* Our team achieved an on-time delivery performance of 97% during this time up from 73%.

Allan W. Kerns

1064 Towne Lake Hills E. Woodstock, Georgia 30189 770-***-**** ******@*******.***

Harding Machine, East Liberty, Ohio 1976 - 1999

* Acme Screw Machine Set up / Operator / Team Leader 1976 - 1994

* Acme Departmental Manager 1994 - 1999

Education

Benjamin Logan High School Graduate

Clark State Community College

Arizona School of Real Estate and Business

Personal and Professional Affiliations

Mayor, City of West Mansfield Ohio

President / Board Member, W.M. Lions Club & W.M. Conservation Club

School Board Member, Benjamin Logan Schools & High Point Joint Vocational Schools

Managed Youth and High School Baseball programs

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