Plant Manager Master Blackbelt Six Sigma
Resume:
SCOTT J BALES
***********@*****.***
Professional Summary
Seasoned Manager with more than 20 years of experience in fast paced multiple diverse manufacturing environments.
Excellent Lean Six Sigma Master Black Belt, T.P.S Certified and Process Improvement skills with a long track record
of achieving exceptional results in Plant Operations.
Skills – Experience Manufacturing – Developing - Processes
Mini Tab
Manufacturing Process Design and Development
Supply Chain / Logistics
Six Sigma Master Black Belt (Japan)
Red X Master Black Belt
Master Lean Manager TPS Certified
PMLPC Project Management Lean Process
TQMP Total Quality Management Professional
SOLC Strategic Organizational Leadership
EMC Executive Management Certified
Heavy Industrial Class A Stamping
Auto Parts
Medical Device Manufacturing
SRS Safety Systems
Aerospace
Woven Materials
New Product Development/Design
R and D
Wind Tunnel / Drop / Break /Weather/ Crush Testing
Food/Beverage High Speed Manufacturing
FDA Experience Aseptic Food- Bev – Pharm – ISO
Quality Control Expert
Chemicals/Plastics/Steel
Precious Metals/Aluminum Casting
Electronics/Circuit Boards/Servers
Work Experience
Manufacturing Multi Plant Manager & Global Master BB Lean Process Engineer
May 2006 Jun 2014 Japan/TX/Mexico/Germany/North America
SDP Diverse Manufacturing Sy-Coson Co
Tier 1, Tier 2, Aero Space, Auto, Stamping, Injection Molding, Food/Bev, Bottling Companies, Pharmacy, Big 3,
Chemicals, Plastics, Steel, Precious Metals, Medical Devices.
Positions Held - Engineer>Quality Control Specialist>Production Line Manager>New Product Development>R and D
Engineer>Plant Manager>District Plant Operations Manager>VP of Manufacturing Multi Plant.
Saved company on average 25% a year (16m) with labor cost savings, by making procedures more lean and
engineering processes less steps, which created higher quality.
Reduced accidents from an average of 10 per year per 3000 workers to less than 1 by revamping the safety
procedures and equipment standards.
Minimized MUDA (waste) at each plant saving the company over 9m per year alone.
Combined Management responsibilities and eliminated 420k a year in payroll and increased efficiency and quality
of work with management staff.
Made sure all plants are following company policy, and are working within Lean Principles.
Managed and had meetings with Production Managers to ensu re Quality and Lean Processes were followed.
Identified opportunities and implemented changes to improve products and reduce costs using knowledge of
fabrication processes, tooling and production equipment, assembly methods, quality control standards, and
product design, materials and parts.
Determined root causes of failures using statistical methods and recommend changes in designs, tolerances, and
processing methods.
Provided technical expertise and support related to manufacturing.
Incorporate new methods and processes to improve existing operations.
Troubleshot new and existing product problems involving designs, materials, or processes.
Reviewed product designs for manufacturability and completeness.
Communicated manufacturing capabilities, produc tion schedules, and other information to facilitate production
processes.
Trained production personnel in new and existing methods.
Designed, installed, and troubleshot manufacturing equipment.
Prepared documentation for new manufacturing processes and eng ineering procedures.
Applied continuous improvement methods such as lean manufacturing to enhance manufacturing quality,
reliability, and cost-effectiveness.
Investigated and resolved operational problems, such as material use variances or bottlenecks.
Manufacturing Multi Plant Manager & Global Master BB Lean Engineer
May 2003 May 2006 Japan/TX/Mexico/Germany/North America
BTK Diverse Engineering Manufacturer Sy-Coson Co - Contract Manufacturer for Lockheed Martin/Boeing/GE/AC
Delco/Northrop/Walmart/J&J/Big 3/Medical/Chemical
Positions Held - Head Engineer>Lean Process Specialist>New Product Development>R and D Engineer>Plant
Manager>General Manager/Manufacturing Multi Plant.
Eliminated old 'out dated' equipment and replaced with n ew fast efficient processes saving the company more
than the equipment in costs and quality in less than 2 years.
Saved company on average 19% a year (11m) with labor cost savings, by making procedures more lean and
engineering processes less steps, which created higher quality.
Reduced accidents from an average of 5 per year per 2000 workers to less than 1 by revamping the safety
procedures and equipment standards.
Minimized MUDA (waste) at each plant saving the company over 2m per year alone.
Made sure all plants are following company policy, and are working within Lean Principles.
Managed and had meetings with Production Managers to ensure Quality and Lean Processes are followed.
Designed testing methods and test finished products and process capabilities to establish standards or validate
process requirements.
Designed layout of equipment and work-spaces to achieve maximum efficiency.
Purchased equipment, materials, and parts.
Evaluated manufactured products according to specifications and quality standards.
Estimated costs, production times, and staffing requirements for new designs.
Investigated and resolved operational problems, such as material use variances and bottlenecks.
Applied continuous improvement methods such as lean manufacturing to enhance manufacturing quality,
reliability, and cost-effectiveness.
Prepared documentation for new manufacturing processes and engineering procedures.
Trained production personnel in new and existing methods.
Reviewed product designs for manufacturability or completeness.
Supervised technicians, technologists, analysts, administrative staff, and other engineers.
Incorporated new methods and processes to improve existing operations.
Provided technical expertise and support related to manufacturing.
Plant Manager – Global Process Engineer Lean May 1988 May 2003
MTA Food Lines - Food/Bev/Pharmacy/Consumer Goods/Medical Device/HBC
Chemicals/Aseptic/Beverages/Food High Speed lines
Saved company on average 9% a year (6.2m) with labor cost savings, by making procedures more lean and
engineering processes less steps, which created higher quality.
Reduced accidents from an average of 3 per year per 500 workers to less than 1 by revamping the safety
procedures and equipment standards.
Education Minimized MUDA (waste) at the plant saving the company over 1m per year alone.
Followed all FDA Rules.
Serve Safe Certified.
Followed OSHA Rules/Ensure all worker safety.
Evaluated manufactured products according to specifications and quality standards.
Estimated costs, production times, and staffing requirements for new designs.
Investigated and resolved operational problems, such as material use variances and bottlenecks.
Applied continuous improvement methods such as lean manufacturing to enhance manufacturing quality,
reliability, and cost effectiveness.
Prepared documentation for new manufacturing processes and engineering procedures.
Reviewed plans and confer with research and support staff to develop new products and processes.
Determined staffing requirements, and interview, hire and train new employees, and oversaw those personnel
processes.
Reviewed financial statements, sales and activity reports, and other performance data to measure productivity
and goal achievement and to determine areas needing cost reduction and program improvement.
Managed staff, preparing work schedules and assigning specific duties.
Directed and coordinated organization's financial and budget activities to fund operations, maximize investments,
and increase efficiency.
Established and implemented departmental policies, goals, objectives, and procedures, conferring with board
members, organization officials, and staff members as necessary.
Education/Certs
1992 Bachelor of Science: Engineering Manufacturing
I have over 93 Certifications, ones listed above and below are ones relevant to the position.
TPS Certified: Toyota Production System Japan 2003, 05, 07,09,11,13
SSMBB: Six Sigma Master Black Belt Japan 2003, 06, 08,10,12,14
Red X Master Black Belt
Master Lean Manager TPS Certified
PMLPC Project Management Lean Process
TQMP Total Quality Management Professional
SOLC Strategic Organizational Leadership
EMC Executive Management Certified
PMQ/ACQ/PRS/PCT
If this conversion to word copy of my resume, is not correct in format, spacing, tabbing, numbering, please email ***********@*****.*** for a new copy
of it. Thank You
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