Manager Sales
Resume:
James P. Kicklighter, Jr. “Jim”
Fort Dodge, Iowa 50501, United States
***************@*****.***
Professional Experience
GEORGIA-PACIFIC GYPSUM LLC, FORT DODGE, IOWA
Plant Manager, April 2013 – April 2015
Recruited to Georgia-Pacific to lead the Fort Dodge, gypsum operation.
A few key accomplishments-
• Led team that successfully commercialized LiteWeight gypsum wallboard at the Fort Dodge plant
resulting in increased sales equal to 75 additional operating days in 2014 vs. 2013 and nearly doubling
EBITDA.
• Led Strategic Planning team including local and corporate resources that developed 5 year plan to
bring the aging facility to ‘state of the art’ within 4 years, increasing production volume by over 50% and
dramatically improving EBITDA.
• Recruited, hired, trained 3rd production crew to meet increased production demand from new products
and improved market conditions – moved operation from 2-3 operating days / week to 5-6 operating
days / week.
• Implemented predictive maintenance processes including Vibration Analysis, Thermography, Oil analysis
programs leading to improved 5% improvement in operating uptime, reduced call outs and improved morale.
• Actively participated in the successful negotiations between Georgia-Pacific and USW resulting in 4 year labor
agreement.
SONOCO, HUTCHINSON, KANSAS
Mill Manager, Jan 2001 – March 2013
Assigned by new ownership of Republic Group to manage the Hutchinson Paperboard mill through the sale
of the Hutchinson, KS mill to Sonoco. This included full P&L responsibility of the operation through 10
months operating as an independent LLC. Asked by Sonoco paper division leadership to remain with the
mill and manage it through the subsequent culture change from Republic Group to Sonoco.
A few key accomplishments-
• Drove the culture change from a ‘top down’ leadership model to a much more highly involved,
participative workforce culture which enabled the success listed below.
• Drove the safety culture change, resulting in injury free performance in 2003, 2010 and 2011 – winning
Best Record in 100% Recycled Mills category for Pulp and Paper Safety Association and over 750,000
consecutive safe man hours from 2009-2012.
• Led strategic capital planning and execution including modernizing process control technology which reduced
finished product variation and enabled reduction in scrap rates by more than 75% in both paper machine processes.
• Sponsored the mill Maintenance Excellence team which has moved from a reactive operating mode to
a strong focus on preventive and now predictive maintenance using modern maintenance practices
including Vibration Analysis, Thermography, Laser Alignment, Oil Analysis, which reduced MRO working
capital by 50%, improved reliability and reduced unplanned outages and callouts by 50% while
improving morale in the department.
• Sponsored the mill Energy Team which has implemented both capital improvements and changed
operating tactics that have lowered natural gas consumption per unit of production by over 40%.
• Led mill focus on continuous improvement and productivity using LEAN methodology and Six Sigma
practices that have resulted in the mill consistently meeting 4% productivity gains annually since 2001.
• Led team of sales, product development and mill production stakeholders to develop new grades and customer
base after exiting gypsum linerboard business replacing 30,000 tons annually with a diverse product mix and average gross
margins near 30%.
• Maintained ISO 9000-2000 certification achieved in 1997 with zero major findings through annual audits by
Lloyds register.
• Actively participated in the successful negotiations of 3 multiyear labor agreements between Sonoco and United
Steelworkers (USW).
REPUBLIC PAPERBOARD, LAWTON, OKLAHOMA
Mill Manager, May 2000 – Jan 2001
Recruited internally by the Republic Group board of directors to relocate to Lawton, OK and lead the Lawton
Paperboard Mill through the startup curve and qualification of new grades at all major customers. This included full
P&L responsibility for 100 % recycled, high speed lightweight gypsum linerboard mill. The Lawton Mill was a
Greenfield startup (November 1999) mill designed to produce lightweight gypsum linerboard. The non-union
workforce was hired and structured to support a “Team Concept Mill”. The mill was sold to Centex Construction
products in November of 2000.
Key accomplishments:
• Reorganized leadership team putting people with key skill sets into positions that best utilized their talents, built
upon their strengths and improved the team performance.
• Led operations, maintenance and engineering team that improved throughput from 265 tons/ day to 585 tons / day.
• Led operations, quality and sales team that qualified key paper grades at all major customers –a key contractual
component that allowed for the finalization of sale of company.
• Implemented behavioral safety observation processes which reversed negative safety performance trend and lead to
multiple months of injury free performance.
• Worked with HR and mill operating leadership team to introduce greater accountability into the workforce while
maintaining the “Team Concept”.
REPUBLIC PAPERBOARD, HALLTOWN, WEST VIRGINIA
Mill Manager, Jan 2000 – May 2000
Recruited away from Sonoco by Republic, given full P&L responsibility and the charge to turn around a poorly
performing operation with two paper machines and a converting department.
Key accomplishments:
• Implemented behavioral safety training and practices that resulted in multiple month injury free performance which
was sustained after my departure to lead Lawton mill.
• Led internal margin analysis team that discovered significant flaws in understanding of product density impact on
sales price per unit which was primary driver of net sales losses of the business – resolved those issues.
• Reduced employee turnover in plant from more than 200% to less than 20% by setting boundaries, implementing
and enforcing attendance control processes and improving hiring practices.
SONOCO, SUMNER, WASHINGTON
Plant Manager, Mar 1996 – Jan 2000
Recruited internally to lead the Sumner mill as part of plan to transform the culture of the Sumner mill from a
conventional ‘command and control’ management style to a more highly involved participative workforce. Key
notes:
• Full P&L Responsibility for 100 % Recycled board mill making primarily tube & core grades.
• Improved net margins from 5% annually to 25+% annually,
• Improved throughput by 22% or over $3MM annually.
• Set all time safe work day record of 2682.
• Drove optimization projects which netted cost reduction of 20%+ in raw material expense.
• Actively participated in the successful negotiations of 2 labor agreements between Sonoco and the Association of
Western Pulp and Paper Workers (AWPPW)
• Completed Six Sigma training and refining optimization project resulting in annual savings of $175k.
SONOCO, TRENTON, ONTARIO CANADA
Production Supervisor, Sep 1993 – Feb 1996
SONOCO, ROCKTON, ILLINOIS UNITED STATES
Process Services Supervisor (I, II & III), Jul 1990 – Sep 1993
SONOCO, HARTSVILLE, SOUTH CAROLINA
Management Trainee, Aug 1989 – Jul 1990
WESTVACO, CHARLESTON, SOUTH CAROLINA
Cooperative Education Student, Aug 1984 – Aug 1988
Education
CLEMSON UNIVERSITY, CLEMSON, SOUTH CAROLINA
BS Chemical Engineering, July 1989
Additional Skills
• Six Sigma Black Belt, 1999
Community Involvement
Leadership Reno County - Class of 2004
Reno County Chamber of Commerce
Executive Board – 2006, 2007, 2008
Treasurer – 2007, 2008
Hutchinson Industrial District #1
Treasurer,, 2001 thru 2013
Boy Scouts of America –Mid America Council
District Chair – Twin Lakes
Contact this candidate