Manager Manufacturing

Les McFarland ***** W. Windsor Ave., Goodyear, AZ 85395

LinkedIn: www.linkedin.com/pub/les-mcfarland/b/7aa/4bb/ 513-***-**** *************@*****.***

Lean Manufacturing Operations Leader: Strategic Planning Operations Engineering Facilities

Highly motivated, natural leader with proven experience and success in managing challenging manufacturing operations with diverse manufacturing processes Consumer Products (Energizer, P&G, BWAY) and Automotive (GM, Tier 1/Tier 2 auto-industry suppliers). This history of success can be attributed to a leadership style and personal vision of creating an environment that enables employees to excel both personally and professionally through learning and meaningful contribution. Proven experience and achievement in the following competencies:

Business/Division Leadership • Plant Management • Strategy Development • New Product/New Process Development and Introduction • Strategic Sourcing • Financial Management/Analysis (Balance Sheet, Income, Cash Flow) • Gross Margin Growth • Business Performance Turn-around • Profitable Business Growth • Lean Manufacturing//Kaizen/TPM/ SMED • 5S Auditor • Knowledge of Six Sigma Methodology • ISO 9000/QS 9000/TS 16949 • Strong Commitment to Safety • STOP/STEP • Cross Functional Team Building and Development • Management of Automated Facility of Electromechanical Equipment.

Experience and Achievements

AMERICAN PREMIER PRODUCTS, LLC – PHOENIX, AZ 2012–2014

Plant Director: Top site-level position responsible for overall leadership for the operations, domestic and international, to produce and distribute baby wipes. Key member of management team responsible for new product development, raw material purchasing, production planning, maintenance and shipping. Report directly to CFO and COO.

ENERGIZER PERSONAL CARE – PLAYTEX PRODUCTS, Sidney, OH 2008–2012

Plant Director: Top site-level position responsible for Ohio operations for the Playtex business unit with three facilities totaling 226,200 sq. ft with $174MM annual sales and employing 135 employees. Overall leadership for the operations to produce and supply Diaper Genie and Wet Ones wipes to the North American Market. Key member of management team responsible for strategic planning and development of the annual business plan for the brand. Report directly to VP of Internal Manufacturing.

ACHIEVEMENTS:

Reduced TIR by 24% year-over-year by focusing on safety awareness through new initiatives, training programs and job safety assessments.

Delivered First Time Quality (FTQ) of 99.8% through establishment of clear accountability and expectations.

Delivered Line Item Fill Rate (LIFR) of 98.3% despite record unforecasted volume demands resulting from pandemic flu outbreak. Response and teamwork exhibited across entire supply chain (marketing, planning, and operations) was hailed as the “new standard” by Sr. Management of Energizer.

Improved OEE by 5% to 79.5% average across all lines while maintaining scrap at targeted levels through continuous improvement efforts.

Identified and implemented cost optimization initiatives delivering $776M on annualized basis. Initiative utilized cross-functional team to evaluate opportunities, probability of success and return on investment. Developed action plans with timelines and assigned accountabilities to ensure successful execution.

Implemented successful Lean and 5S programs. Achieved parity after a year with Energizer North American facilities that began their efforts five years ago. Site is acknowledged as the leader in many areas and served as a pilot plant for several trial programs for the business unit. Personally selected to be 5S auditor for both domestic and international sites.

BWAY CORPORATION, Cincinnati, OH 2005–2008

Plant Engineer / Operations Manager: Key leadership position, directing coil line, project engineering, plant maintenance and machine shop for a high-speed, lean manufacturing, aerosol can manufacturing operation (500,000 sq. ft, $80MM annual sales, 300 employees on 24/7 operation). Report directly to Chief Executive Officer, four direct reports and 65 indirect reports. Hired as part of new management team to turn around an underperforming facility.

ACHIEVEMENTS:

Reduced key process downtime by 65 percent annually resulting in $312K annual savings in lost productivity.

Implemented equipment/process quality improvements reducing customer complaints regarding customer specific issue to zero.

Leadership in Kaizen events for Smart Changeover (SCO) and 5S resulting in cost savings and higher operating efficiencies.

Member of various steering committees to increase plant wide quality awareness, productivity, safety and profitability.

INTERNATIONAL FINEBLANKING, Dayton, OH 2000–2005

Engineering Services Manager: Staff-level management position, directing project engineering, process engineering, and plant maintenance for a high-precision, lean manufacturing, metal-stamping operation (174,000 sq. ft, $22MM annual sales, 150 employees on 3 shifts). Key customers include Ford, GM, and other auto-industry manufacturers. Reported directly to General Manager.

ACHIEVEMENTS:

Increased manufacturing capacity through addition of two new work cells. Performed research, justified capital expenditure, designed layout, and oversaw installation of production capacity that correlated to $3MM–$4MM additional revenue yearly.

Delivered $1.6MM manufacturing expansion on time, under-budget, and with more amenities than originally contracted. Defined requirements, selected contractor, and coordinated project through completion. The 64,000-sq.-ft. expansion increased manufacturing floor by 50%.

Championed design and implementation of the Environmental Management System (EMS) and successful ISO 14001 registration effort. Played an active role in QS9000 and TS16949 quality programs.

Selected to manage plant closing. Relocated all major equipment and integrated operations into existing production facilities in three states. Managed environmental issues and facility clean-up.

GENERAL MOTORS CORPORATION, Norwood, OH

Journeyman Pipefitter / Inspection Supervisor / Final Quality Auditor

Professional Profile

EDUCATION:

MBA, Franklin University, Columbus, OH

BS in Applied Management, summa cum laude

Franklin University, Columbus, OH

AAS in Manufacturing Engineering, magna cum laude

Cincinnati State Technical and Community College, Cincinnati, OH

TECHNICAL TRAINING:

SME Value Stream Mapping Webinar: 3-part webinar detailing VSM process

Fundamentals of Manufacturing Examination: Completed review course and passed SME examination.

GM/UAW Skilled Trades Apprenticeship Program: Completed 7328 shop training hours and 572 related classroom training hours; earned Journeyman Pipefitter designation.

GM Supervisory Training Program: Completed detailed 6-month in-house training program.

PROFESSIONAL AFFILIATIONS: Society of Manufacturing Engineers; American Production and Inventory Control Society

ADDITIONAL EXPERIENCE: Adjunct Professor Engineering Technology Division, Cincinnati Technical College : Instructed evening courses for the Manufacturing Engineering program and Productivity Improvement Center.

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