Operations Leader, Lean and Plant Manager, Supply Chain Director
Resume:
Russ Toman
Brookfield, WI **045
acof2z@r.postjobfree.com
DYNAMIC Operations Leader
Highly competent, results-oriented plant manager with demonstrated
expertise in:
P&L / Financial Controls
Staff Management & Development
Cost Control/Efficiency Strategies
Project Management
Work Cell Layout Flow
Purchasing / Material Control
ERP Systems
Distribution / Supply Chain
Lean Cellular Work Cells / Kaizen
Six Sigma / QS / ISO / Quality
KanBan / Inventory Systems
Policy/Procedure Development
An exceptionally resourceful, proactive and strategic management leader
with a proven track record for increasing profit margins while maintaining
high quality projects completed on time and within budget constraints. Able
to communicate positively and clearly and to encourage effective
collaboration with personnel at all levels - from shop floor employees to
upper management. Specializing in outstanding quality control, process
improvement and lean operations in service and product companies, work cell
production, engineering operations, inventory and supply chain, budget
controls, and administrative compliance to company policies and goals.
Known for a goal-oriented, strategic systems approach and laser focus in
rapid identification and resolution of problems and challenges.
Experience:
Partner and Senior Operations Lean Implementation Leader
Industrial Systems and Re-engineering Services, Lisle, IL and Brookfield,
WI 2008 - present
. Offer companies a full range of project management services that focus
on leading employee teams in service, quality, engineering, financial
leadership, and key products, purchasing and lean manufacturing/Six
Sigma methods to achieve higher levels of performance, productivity
and profitability.
. Consult and coach business owners and managers in using proper tools
and best practices for lean manufacturing, Six Sigma, QRM and supply
chain methods.
. Specialize in establishing and reinforcing quality assurance based on
relentless, pro-active efforts to understand, listen to and learn from
the customer.
General Manager
Antech Corporation, Tucson, AZ 2007
. Directed day-to-day operations, engineering work based on customers'
product specifications and work flow.
. Was directly responsible for managing and controlling the quality
assurance of products.
. Managed work cell supervisors in the plant as well as on-site field
technicians.
. Saved $150,000 by reducing COGS (cost of goods sold).
. Managed all information systems to ensure accurate analytics and
decision making.
. Improved cash flow and accounting records and increased profitability.
. Led engineering design for manufacturing, work cell flows, component
parts assembly and plant efficiency.
. Reduced costs by 35% through Lead Time reduction in flow design and
purchase of new automation equipment.
. Improved on-time part shipments from 75% to 95%.
. Reduced scrap and minimized rejects, resulting in a savings of 20%.
. Integrated delivery assurance system to match flexible customer
shipment schedules and meet cash flow objectives.
Project Plant Manager *
Cummins Engine, Mineral Point, WI; Columbus, IN 2006-2007
. Reduced cycle times by 50% in less than four months using Toyota, TPS
lean, Six Sigma cellular work flow, increasing production efficiency
by 35%.
. Implemented: root cause analysis in solving problems, closed loop
corrective action plans, more efficient data collection, measurements
improving decision support and analytics that improved quality and
reduced costs.
. Created new tool, die, and jig design to support high performance lean
manufacturing operations.
. Implemented Andon board measurements and new subassembly cells to
improve efficiencies. This resulted in a reduction of 100 man hours of
labor and a 27% reduction in work in process inventory.
. Designed standard work processes and the specific instructions for
plant work cells and office team members.
RUSS TOMAN RESUME - 2
Project Operations Cost Controls Engineering *
Rockwell Automation, Milwaukee, WI 2005
. Managed bill of material costing reviews and analysis, raising
accuracy to 95%.
. Assisted in ensuring compliance with Sarbanes-Oxley guidelines.
. Managed the most complex and high value physical inventory for
financial year-end auditors.
Plant and Distribution Management
Leepers Corporation, Chicago, IL 2004-2005
. Increased working efficiencies by 50%, streamlining workflow methods
and saving $150,000.
. Improved work cells in fabrication, picking, packing, and logistics
processes, achieving a high level of accuracy leading to 85% to 95% on-
time deliveries.
. Achieved new level of sales processing volume from Chicago location,
increasing shipments by 33% and decreasing errors by 25%.
. Saved $70,000 in inventory by using cycle counting and audits.
. Principal in selecting new 90,000 square-foot site and prepared plant
and warehouse layout, accommodating logistical growth requirements.
Plant Manager and Operations Leader
Advanced Die Casting, Milwaukee, WI 2002-2004
. Restructured production scheduling to increase operating efficiencies
in response to variations in sector sales.
. Launched Six Sigma, Kaizen methods, lean manufacturing and continuous
improvement initiatives.
. Reduced scrap by 17%, resulting in savings of $255,000.
. Became Team Champion for lean manufacturing, work cells, and
implemented "KanBan" pull, which achieved inventory reduction of
$400,000.
. Achieved ISO/QS9000 Quality Certification and ensured compliance and
consistency with all ISO 9000 standards, industry standards and
documentation manuals.
. Coached teams to complete standardized processes, streamline flow,
redefine supply chain implementation and develop robust pull systems
in secondary operations.
. Reduced overhead costs by 35% and saved $500,000 by restructuring
shift operations, reducing inventory levels, and implementing
strategic outsourcing for specific secondary work and services.
. Managed the Quality Supervisor responsible for inspection, quality
control testing, methods and procedures.
Manufacturing Project Leader
RHI Management Resources, Milwaukee, WI 2000 - 2002
. Increased gross profit margins by 20% on important volume products
through implementation of lean manufacturing/Six Sigma and supply
chain project management methods.
. Implemented Pareto analysis in job-costing review on all products to
refocus lean manufacturing.
. Completed Kaizen events used to reduce non-value activities in product
cost.
. Designed and supervised final inspection and audit and control process
before products were shipped to customers.
Plant Manager
Ellsworth Corporation, Germantown, WI 1999-2000
. Created production floor work cells and measurements for process
improvement cost saving.
. Set up work value stream work flow by family of parts, saving 30% of
production costs.
. Reduced lead time by 25%. Changed to single piece flow process from a
batch and wait method.
. Oversaw ERP system selection and implementation.
. Tracked all team metrics for departments, division and company level
reporting.
. Created visual quality control processes and checking systems for each
work cell.
RUSS TOMAN RESUME - 3
Principle Project Leader *
SNC Manufacturing Company, Oshkosh, WI 1997-1999
. Served as material control and inventory management leader.
. Created P & L for operating financial controls.
. Oversaw production performance optimization.
Principle Project Leader
Operations and Accounting Solutions, Oshkosh, WI 1992-1997
Provided project leader services to implement:
. Lean Six Sigma manufacturing
. Financial controls
. Performance optimization
Operations / Accounting Manager
Oshkosh Truck, Oshkosh, WI 1990-1992
. Responsible for manufacturing operations and financial management of
the Oshkosh chassis plant located in Greenville, South Carolina.
* These positions were held as a contracted Project Manager.
Education:
Master's in Business Administration, Operations Management, Roosevelt
University of Chicago
Bachelors in Business Administration, Accounting and Finance, University of
Oklahoma
Other training and education completed through:
. Chicago Deming Association-Six Sigma Masters Program, Chicago
. American Society of Quality
. Association of Production and Inventory Control Society ( APICS )
. Society of Manufacturing Engineers ( SME )
. QRM, Quick Response Manufacturing, University of Wisconsin
. Supply Chain Analyst Certification, International Supply Chain
Alliance
SOFTWARE COMPETENCIES:
. SAP
. JD Edwards
. Oracle
. Epicor
. MS Word
. MS Access
. MS Project
. MS Excel
STRENGTHSFINDER 2.0 FIVE TOP STRENGTHS:
. Strategic
. Learner
. Achiever
. Responsibility
. Futuristic
References available upon request.
Contact this candidate