Manufacturing Plant Manager
Resume:
BRAD DeBAUGE
Shawnee, Kansas 66227
913-***-**** Home ****.*******@*****.*** 816-***-**** Cell
Summary:
Hands on manager with 12+ years of production management, manufacturing process improvement, lean manufacturing,
financial budgeting and analysis, and inventory control. I work collaboratively with subject matter experts to diagnose
problems, identify key issues, and develop solid, sustainable solutions. I have participated in Kaizen events, process and
value-stream mapping, Rapid Action Teams, and DMAIC projects. I have led the site safety program, dealing with OSHA
to maintain the site VPP Star certification, and have performed Tap Root incident investigations.
Valspar Corp, Kansas City, Missouri 2005-Pres.
PLANT MANAGER 2012-Pres
• Determined and modified hours of production in order to meet customer demand with lowest possible labor cost, resulting in an
80% decrease in production overtime from 2012 to 2013 though production decreased by only 6.8%;
• Presently managing all on-site closure activities including facilitating product transfers, records retention, personnel changes,
equipment transfers, etc.
• Responsible for all site safety related items including committee meetings, regulatory training, incident investigation and
completion of all corrective actions. Maintained site OSHA VPP status achieved in mid 2012;
• Work with outside contractors to ensure timely submission of all regulatory environmental submissions.
• Managed all hazardous, universal, and special waste profiles for disposal;
• Plan and conduct regularly meetings with Union Leadership Team to communicate business trends and to negotiate resolutions
to labor related grievances. Negotiated site closure agreement and effects on Union personnel;
• Create and monitor adherence to site budget and prepare budget projections based on forecasted demand levels.
• Facilitate LSS Yellow-Belt projects throughout the production area for the purposes of improving safety and productivity.
INTERIM PLANT MANAGER (3 months, 2011) SHANGHAI, CHINA
• Overall responsibility for plant operations at powdered paint production facility.
• Instituted scheduled Preventative Maintenance program for all production equipment in the facility.
• Formalized the scheduling process to improve efficiency, run rates, and communication of planned completion dates
between production and sales/customer service.
• Analyzed limitations of current equipment and made recommendations for upgrade of wear parts to improve safety,
quality, and durability.
• Instituted daily safety huddles with production operators to improve knowledge of site safety policies.
• Reduced risk inventory by 25% by analysis and disposable of un-recoverable defective production, reducing carrying
costs of defective inventory and exposure to possible chemical spills.
PRODUCTION MANAGER 2008-2012
• Overall responsibility for meeting production, safety, and budgetary goals for three shift production facility with 4 salaried
supervisors and 60 union-represented hourly workers. Primary liaison between the Company and the Union on labor disputes.
• Researched and redesigned the mixing process resulting in a 25% decrease in extrusion and milling downtime due to “no
material”. Result was an 8% reduction in overtime for production employees.
• Chairman of site Safety Committee. Designed and conducted safety presentations for the site while also conducting annual
reviews of all site safety policies.
• Wrote, reviewed, and updated production related ISO procedures.
• Redesigned the hourly work schedule after downturn in business in order to maximize production efficiencies while allowing
the site to reduce to two shifts, improving productivity by 67% with no increase in headcount or overtime, increasing on-time,
in-full delivery of products to customers.
Valspar Corp, Kansas City, Missouri, Production Manager (Cont.) 2005-Pres.
• Developed Summative Assessments for all production departments and implemented their use as the primary determinant of
employee qualification
• Integral in design and installation of capital upgrades. Project managed capital projects involving equipment installation and
structural upgrades. Installed media blast cabinet utilized for cleaning of internal production parts which resulted in a 40%
decrease in turnover time.
• Managed site cycle-counting process which enabled Kansas City to become the first Valspar General Industrial site to achieve
Physical Inventory Exemption, and have maintained that status for three years. Kansas City was the first Valspar Industrial site
to achieve this exemption and remains exempt through present day.
• Served as a member of a Corporate Rapid Action Team (RAT) which developed a set of guidelines and best practices which
sites could follow in effort to achieve physical inventory exemption
• Responsible for interviewing, hiring, discipline, and termination of production employees.
• Received 2010 Valspar Award of Excellence.
PRODUCTION SUPERVISOR 2005-2008
• Supervised 15-20 union workers in a production environment.
• Instrumental in decreasing yield loss by 42% resulting in $520K of material savings per year.
• As part of a team, guided the production force through emphasis on procedures to decrease defective production by 50% from
FY’05 to FY’06. Continued emphasis led to a further 8% decrease by end of FY ’08.
• Lean/Six Sigma Green Belt trained.
• Held daily safety huddles/production meetings with all shift employees.
• Enforced company attendance/performance policies.
Paxton Wood Source, Kansas City, Missouri 1999-2004
INDUSTRIAL SALES REPRESENTATIVE 2002-2004
• Increased lumberyard sales by 10% from 2002 to 2003 and 25% in 2004.
• Implemented training sessions in material return and computer utilization for quality control.
• Instrumental in obtaining Jeld-Wen “Best in Group” quality award in 2003.
OPERATIONS MANAGER 1999-2002
• Supervised more than 30 union warehouse workers, drivers, and mill workers.
• Coordinated maintenance and repair of vehicles, equipment, and facility.
• Negotiated and managed vendor contracts.
• Scheduled customer deliveries on 10 truck routes in 4 different states.
• Established and implemented quality control procedures for order pulling and production.
• Scheduled production of custom mouldings and wrote scheduling procedures.
Unified School District # 284, Cottonwood Falls, Kansas 1994-1999
HIGH SCHOOL MATHEMATICS INSTRUCTOR, DEPARTMENT CHAIR
• Instructed more than 90 high school students per year; designed curriculum.
• Established programs for out-of-class tutoring and college prep evening courses.
• Developed grade level assessments to track student and program achievement.
EDUCATION
B. S., Business Administration and Accounting
University of Kansas
B. S. E., Secondary Mathematics Education
Emporia State University
Executive Masters of Business Administration (EMBA)
Rockhurst University
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