Manager Maintenance

CHARLES SMILEY

*** ********* ***** **********, ** 46112 Cell: 317-***-****

***************@*****.*** www.linkedin.com/in/charlessmiley

GENERAL MANAGER / DIRECTOR MANUFACTURING OPERATIONS

Highly energized leader with 19 years of success at Alcoa in manufacturing operations management, production, and maintenance in union and non-union, national and international environments along with 5 years of entrepreneurial experience building and managing a start up business in the healthcare industry.

Successful at attaining and sustaining quantifiable bottom line results by engaging people, and securing personal commitment and ownership of business objectives.

Skilled at team building and conflict resolution among cross functional and multi-cultural teams.

AREAS OF EXPERTISE

Operations Management Lean Manufacturing Maintenance Systems Quality Systems Customer Service

Production and Inventory Control Cost Control Project Management Kaizen Total Productive Maintenance (TPM)

Problem Solving Team Building and Leadership Conflict Resolution

COMFORCARE HOME CARE 2009 Present

ComForcare Home Care (www.comforcare.com) specializes in providing a wide range of personalized non-medical home care and support to the elderly, with franchise offices throughout the US, UK and Canada.

Franchise Owner and President Indianapolis, IN

Started up a franchise-based Non-Medical Home Care business targeting the 55 plus population in the Indianapolis area. Hired, trained and managed a staff of 25-30 caregivers and support personnel.

▪ Developed long-term referral relationships with hospitals and health care providers, growing sales from $26K in 2009 to more than $374K. Achieved 500 and 1,000 billable hours milestones.

▪ Held full P&L responsibility for business operations including Accounting, Marketing, Sales, Recruiting, Training, Scheduling, and Client Relations.

ALCOA INC. / ALCOA CSI 1989 2008

Alcoa Inc. (NYSE:AA) is a provider of lightweight metals, products and solutions to the automotive, aerospace, construction, consumer electronics, packaging, defense applications, and oil and gas industries. Alcoa CSI was created through the unification of Alcoa's worldwide metal closure and capping equipment businesses. In 2008, Rank Group Limited acquired Alcoa's Packaging Group, including Alcoa CSI.

Director, Global Maintenance & Reliability, Alcoa CSI Indianapolis, IN (2005 2008)

Promoted to direct the company s Global Maintenance & Reliability efforts across 26 plants in 6 global regions, closely collaborating with plant managers and maintenance leaders in North America, South America, Asia-Pacific, Africa, the Middle East, and Europe.

▪ Implemented a common maintenance and reliability system across 26 plants in 6 global regions that improved reliability excellence, increased manufacturing efficiencies through reduction of downtime and increased output, and lowered inventory and maintenance costs.

▪ Managed a project that decreased scrap by 71%, increased uptime by 9% and increased volume by 22%, generating over $425K in conversion revenue.

▪ Purchased and led implementation of a Computerized Maintenance Management System across North America.

▪ Implemented standardized lubrication and preventive maintenance practices.

▪ Established a common predictive maintenance system, utilizing thermography and vibration analysis.

▪ Introduced a standard process for retrieving performance data from global shop floor system.

▪ Benchmarked best performing plants and developed gap analysis in poorer performing plants, greatly improving manufacturing metrics.

ALCOA INC. / ALCOA CSI (continued)

Plant Manager, Alcoa CSI Olive Branch, MS (2000 2005)

Operations Manager, Alcoa CSI Olive Branch, MS (2000)

Directed all ongoing operations through a staff of 165 employees which included: Production, Environmental, Health and Safety (EHS), Quality, Maintenance, Engineering, Planning and Inventory Control, Capital, Cost, Human Resources and Contract functions. P&L responsibility for annual sales of $8.1M. Ensured compliance with OSHA requirements, housekeeping and environmental health and safety activities.

Earlier, as Operations Manager, managed day-to-day production, with responsibility for 4 Shift Supervisors and 120 hourly production employees operating 30 compression molders.

▪ Eliminated $721K of waste in repair parts and stores inventory through reduction in equipment downtime, tighter inventory control, and the sale of spare parts to other locations.

▪ Achieved 26% overall cost improvement by maintaining business momentum and effectively managing expenses.

▪ Successfully reduced overall manufacturing scrap by 44% by standardizing work, resolving manufacturing issues, and installing process monitoring devices.

▪ Gained a 13% improvement in manufacturing output through equipment reliability improvements, standardized work, and implementation of an In Control and Capable (IC&C) quality system which reduced customer complaints by 39%.

▪ Established Alcoa Business System based on Toyota Production System, implementing Rules In Use, Standardized Work, Problem Solving, Daily Management, Pull Systems, 5S, Kaizen, TPM and Waste Elimination.

▪ Reduced overall manufacturing costs that resulted in the plant being awarded a $5M capital investment to launch a new product line. Project was implemented early and within budget.

▪ Reduced first aid injuries by 50% through employee engagement, elimination of unsafe conditions, and employee reward and recognition programs.

▪ Completed over 1 million hours without a lost work day in 2004.

Prior Positions, Alcoa CSI Newburgh, IN (1989 2000)

Began career with Alcoa as an Intern in Electrical Maintenance. Held various positions of increasing responsibility in maintenance and production from start of the manufacturing process (smelting/ingot) to finish (packaging/shipping). Final position held was as Maintenance Services Superintendent.

▪ Improved scrap recovery resulting in $250K in annual savings.

▪ Supervised electricians in the rebuild of the electrical system after a devastating fire. Completed rebuild in 6 weeks instead of the expected 8 to 12 weeks.

▪ Coached and developed production and maintenance personnel in a semi-autonomous work environment.

▪ Led mechanics and electricians in a 7-week rebuild of a large crusher; completed project with zero injuries and ahead of schedule.

EDUCATION

M.A., Applied Behavioral Sciences, Emphasis on Managing and Consulting, Bastyr University, Seattle, WA, 1997

B.S., Electronics Technology, Indiana State University, Terre Haute, IN, 1988

Certified Senior Advisor, Society of Certified Senior Advisors, 2010

PROFESSIONAL / COMMUNITY INVOLVEMENT

Vice President, Hendricks County Council on Aging

Advisory Council Member, Central Indiana Council on Aging (CICOA)

Member, Kiwanis Club of Brownsburg

Contact this candidate