Operations/Plant Management
Resume:
**** ******* ***** (***) *** -
*********@*****.***
Keith W. Sawyer
Objective Leadership position guiding an Operations/ Production/Engineering team
providing the opportunity to employ the skills, abilities and expertise I
Qualificatio have gained and demonstrated through my education and career
ns accomplishments.
Demonstrated success in leading an organization at the plant level through
difficult business conditions while dramatically improving safety, quality,
reducing costs and maximizing productivity.
Expert ability to develop technical professionals into a cohesive unit
providing a strong foundation upon which operational excellence was
achieved.
Extensive knowledge and accomplishments in all aspects of operations
execution, budget preparation and management at the plant and corporate
levels.
Demonstrated abilities to effectively interact and communicate with senior
executive team members, all levels of management, production personnel,
customers and external vendors & contractors regarding all aspects of a
manufacturing environment.
Professional September 2012 - Current - syncreon-U.S., York PA
experience Operations Manager - Logistics Supplier for Harley Davidson Motrocycles -
Inventory, Assemble & Sequence Parts to Harley Davidson Assembly Line
Responsible for all aspects of the management and scheduling of a two (2)
shift operation of 520 union associates to meet Harley Davidson's
production requirement
Responsible for (18) Salaried Supervisors & (2) Salaried Production
Managers
Responsible for developing and implementing safety, quality and operation
improvement initiatives
Implemented scrap reduction program featuring one by one root cause method.
Reduced monthly scrap from $80,000 to $20,000
Successfully coordinated relocation of 400,000 sq ft operation with no
impact to Customer,
Successfully launched new MY14 program in July 2013, meeting condensed
customer timing
Developed system to more effectively track customer driven OT to ensure
that all costs were recouped resulting in improved monthly EBITDA results
March 2011 - April, 2012 - Magna Composites, Salisbury, NC
Engineering Manager - Salisbury/Newton, NC Facilities - Heavy Truck
Composite Components - Molding, Machining, Bonding, Assembly and Painting
Responsible for the oversight of a Program Engineering Group of six (6)
engineers responsible for implementation of advanced planning, equipment
design and coordination of new program launches; providing design and
development support for cost and process improvement initiatives; Cost
estimating for all current and future programs.
Developed manufacturing plan to successfully launch the 2013 Kenworth Heavy
Truck Sleeper Roof. Met or exceeded PACCAR's build dates and requirements,
as well as ensuring compliance with Magna's TS 19649 procedures and
processes. Launch Date - May 2012. Responsibilities included product
costing, processes & capacity planning, tooling and capital requirement
planning. - $6.8 Million in Annual Sales
Successfully launched the 2012 Mercury Marine 150 HP Engine Cover Program.
Met Mercury Marine build dates and requirements, within budget.
Responsibilities included product costing, processes & capacity planning,
tooling and capital requirement planning. Program was challenging due to
being designed four (4) years prior to launch and sitting idle for (2)
years. Required to accommodate late design changes and still meet launch
timing - $5.0 Million in Annual Sales
Developed system to identify and track cost improvement opportunities. $7.0
Million in annual savings opportunities identified since May 1, 2011.
Projects totaling $2.4 Million in projected savings for 2012 have been
implemented and $4.0 Million identified as opportunities focusing on
process and operating improvements Material, Labor and Scrap.
July 1, 2010 - March 21, 2011 Ventra - Ionia, LLC, Ionia, MI
Manufacturing Engineering Manager - Ionia Facility - Steel Bumper Systems -
Stamping, Machining, Plating, Painting & Assembly
Developed and Managed an effective Manufacturing Engineering Group of eight
(8) professionals responsible for implementation of advanced planning,
equipment design and coordination of critical new program launches for
organization; providing design and development support for cost and process
improvement initiatives; Accurate cost estimating for all future programs.
Identified and tracked $3.5 Million in annual savings opportunities in
2010. Projects totaling $926K annually implemented July 2010 - March 2011
focusing on process and operating improvements Material, Labor and Scrap.
Developed strategic manufacturing plan to successfully launch the 2013 Ford
Taurus Chrome Grille assemblies in July 2012. Responsibilities include
product costing, processes & capacity planning, tooling and capital
requirement planning.
Responsible for actively managing Product Data Management (PDM), including
routings, BOM's, production standards, FMEA's, and plant capacities for
future and current programs.
October, 2009 - July 1, 2010 Ventra - Ionia, LLC, Ionia, MI
Plating Manager - Ionia Facility - Steel Bumper Systems - Stamping,
Machining, Plating, Painting & Assembly
Responsible for the development and oversight of an effective Plating
Department Group of twenty seven (27) salaried associates and one hundred
(100) hourly union associates. Responsible for the Plating Lab & Quality,
Production, Maintenance and Plating Controls.
Ensured Plating department prepared for plastic plating production level
increase to 89,000 plated parts per month in June 2010 from 8,700 parts per
month in 2009 with no significant erosion in FTC of 86%.
Successfully developed staffing and training levels to meet GM, Chrysler
and Ford requirements to provide plated plastic and steel parts to
specifications. Implemented third shift plastic plating in April 2010.
Coordinated and Implemented manufacturing plan to launch the Ford 2011
F250/350 Super Duty front plastic plated grille assembly in January 2010.
Program met all milestone dates and met or exceeded customer expectations.
Program launched with minimal quality concerns and met customer delivery
schedules. Approximately $11.9 Million in annual revenue
Coordinated manufacturing plan to launch the GMT Super Duty
Chevy/GMC/Denali plastic plated front grille assemblies in April 2010.
Program has met all milestone dates and met or exceeded customer
expectations. Program launched with no significant quality or delivery
concerns. Approximately $7.9 Million in annual revenue
Developed and implemented a level load schedule program for plastic plating
to provide clear and definitive production goals & objectives to management
as well as production associates. Line load efficiency increased from 77%
in March 2010 to 89% in July of 2010.
August, 2008 - October, 2009 Ventra - Ionia, LLC, Ionia, MI (Became part
of FNG July 2009)
Facilities & Engineering Manager - Ionia Facility - Steel Bumper Systems -
Stamping, Machining, Plating, Painting & Assembly
Responsible for a Manufacturing Engineering Group of thirty (30)
professionals responsible for implementation of advanced planning,
equipment design and coordination of critical new program launches for
organization; providing design and development support for cost and process
improvement initiatives; Cost estimating for all future programs; facility
infrastructure, capital refurbishments and management; MRO Inventory
Management
Developed and managed manufacturing plan leading to the successful launch
of the 2010 Ford Taurus Chrome Grille assemblies in July 2009 meeting
Ford's build dates and requirements. Responsibilities included all
processes, tooling and capital requirement implementations.
Developed and managed manufacturing plan to launch the Ford 2011 F250/350
Super Duty front grille assembly in January 2010. Program has met all
milestone dates and met or exceeded customer expectations. Responsibilities
included all processes, tooling and capital requirement implementations.
Developed and managed manufacturing plan to launch the GMT Super Duty
Chevy/GMC/Denali front grille assemblies in April 2010. Program has met
all milestone dates and met or exceeded customer expectations.
Developed plan and managed transfer of Current Dodge Ram Front bumper
program to Ionia from another FNG Facility in a (2) month time frame
without negative impact to Chrysler quality or delivery.
January, 2006 - August 2008 Meridian Automotive Systems, Ionia, MI
Plant Manager - Ionia Facility - Steel Bumper Systems - Stamping,
Machining, Plating, Painting & Assembly
Successfully developed and lead an effective and efficient Management Team
increasing performance in the areas of Safety, Quality and Cost
Improvement, achieving challenging organizational objectives and targeted
business performance metrics.
Achieved successful consistent record for reducing the level of recordable
incidents from 124 in 2005 to 77 in 2006 to 58 in 2007.
Successfully and repeatedly achieved superior results in exceeding
challenging business goals surpassing EBITDAR target of 19.2% achieving
20.3% in 2006 on Sales of $185 Million and again in 2007 exceeding goal of
22.0% and achieving 23.7% on Sales of $181 Million. Superior results
achieved through the application of MBS Kaizen Events, strategic Labor
Management initiatives and significant process improvements.
Reduced overall Plant Inventory in 2006 and 2007 by over $5 million;
reduced raw material by $2million; reduced vital Nickel inventory by 176K
lbs.
Achieved significant reduction in 2007 Overhead Costs reducing related
expensed by $8 million representing approximately 4% of Sales in 2007.
Responsible for leading strategic development and implementation of Plastic
Plating Process which made possible an additional $30 Million in Sales for
2008.
October, 2003 - January, 2006 Meridian Automotive Systems Ionia, MI
Industrial & Manufacturing Engineering Manager - Steel Bumper Systems -
Stamping, Machining, Plating, Painting & Assembly
Responsible for the development, implementation and oversight of an
effective Manufacturing Engineering Group of fifteen (15) engineers
providing increased support for cost and process improvement initiatives;
implemented advanced planning, equipment design and coordination of new
program launches for organization.
Successfully undertook responsibility for $7.0 million initiative involving
program and facilities equipment and related process implementation,
including overall management responsibility of internal WIP rack fleets for
all programs.
Designed and implemented multiple process improvements resulting in over
$900,000 annual savings for the organization in 2004.
Developed, implemented and managed strategic manufacturing plan leading to
the successful launch of the 2004 F150 Ford front and rear bumper
assemblies meeting Ford's critical milestones as well as ensuring
compliance with Meridian's QS-9000 and Ford Q-1 procedures and processes.
Responsible for managing Product Data Management (PDM) for five (5) FEM/REM
facilities, including routings, BOM's, production standards, FMEA's, and
plant capacities for future and current programs.
June, 2000 - October, 2003 Meridian Automotive Systems Ionia, MI
Manager of Plant Engineering for Exterior Plastics
Responsible for providing lead process, facility and construction
engineering management of eleven (11) multi-million $ SMC molding
facilities with annual capital budgets: 2003 - $13.5 Million. 2002 - $9
Million. 2001 - $8 Million. 2000 - $6.1 Million
Project Highlights
Designed, upgraded and relocated multi-million $ SMC (Sheet Molded
Compound) process to a refurbished facility in Grabill, IN - Complete May
2003. Capital: Building - $2.5 Million, Process upgrades & relocation -
$3.9 Million.
Designed and implemented an ultraviolet coating system, including upgraded
paint system, meeting GM specifications in Grabill, IN Facility. Met
expedited startup timeframe condensed to five (5) months to meet customer's
required program timing. Complete - June 2003. Capital: $2.3 Million.
Undertook Salisbury, NC Plant expansion to meet customer needs. Complete -
November 2003. Capital: $5.6 Million
Oversaw construction of Celaya, Mexico SMC molding facility and
implementation of new SMC Molding Operation. Coordinated transfer of
multiple programs for production. Coordinated installation of SMC prime
paint line. 2000 through 2002.
July, 1998 - June, 2000 Meridian Automotive Systems Ionia, MI
Manager of Industrial Engineering - Steel Bumper Systems - Stamping,
Machining, Plating, Painting & Assembly
Developed and managed IE Department of two (2) engineers focusing on
designing and implementing process improvements, Bills of Materials and
Routings accuracy; achieved results improving inventory tracking and
standard costing, accurate future program costing proposals for four (4)
Meridian facilities and launch and maintenance of MAPICS operating system
in Meridian facilities.
May, 1997 - July, 1998 Hayes-Lemmerz International, Inc. Howell, MI
Facilities Manager - Cast Aluminum Wheels. Casting, Machining & Painting
Lead a team of 31 (four (4) salaried project engineers, three (3) salaried
maintenance supervisors and twenty-four (24) hourly union general
maintenance associates) providing support in the production of cast
aluminum wheels. Responsibilities included day-to-day operations, capital
project planning and implementation, operation reliability improvements,
TPM systems, and facility maintenance and improvements.
May, 1995 - May, 1997 Hayes-Lemmerz International, Inc. Howell, MI
Facilities Engineering Supervisor- Cast Aluminum Wheels. Casting, Maching
& Painting
Lead a team of 4 ( two (2) salaried project engineers, one (1) facilities
technician and one (1) intern) responsible for the development and
implementation of capital projects, facility improvements, maintain
operation work standards and costs and provide manufacturing process
support.
August, 1994 - May, 1995 Hayes-Lemmerz International, Inc. Howell, MI
Industrial Engineer- Cast Aluminum Wheels. Casting, Maching & Painting
Responsible for successful implementation of work standards for machining
operations in a UAW environment. Managed implementation of acrylic clear
coating capabilities project for cast aluminum wheels. Implemented bulk
nitrogen storage and delivery system reducing annual nitrogen costs by
$132K.
March, 1994 - August, 1994 Ironton Iron, Inc (Division of Intermet)
Ironton, OH Industrial Eng
Responsible for developing and maintaining production standards.
Supervised implementation of rust preventative tumbler to replace drip line
resulting in annual material savings of $160,000.
August, 1990 - November, 1992 Frasier & Jones Co Syracuse, NY
Industrial Engineer
Responsible for developing and maintaining production standards, process
improvements, and development of capital projects.
February, 1988 - August, 1990 Grinnell Corporation Columbia, PA
Manufacturing Engineer
Responsible for developing and maintaining production standards, process
improvements, and development of capital projects. Key responsibility in
development and justification of successful installation of $10 million
foundry mold operation.
July, 1981 - February, 1988 Crouse-Hinds Company Syracuse, NY
Manufacturing Engineer
Responsible for developing and implementing process improvements.
Education 1977 - 1981 State University of New York @ Buffalo Buffalo, NY
Bachelor of Science - Industrial Engineering
Minor - Psychology
Professional American Institute of Industrial Engineers
memberships
References Available upon request
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