Abiye Maclayton

Operational Excellence Manager, North America - GREIF INC, North America

Houston, TX

acpys2@r.postjobfree.com - 229-***-****

WORK EXPERIENCE

Operational Excellence Manager, North America

GREIF INC, North America - Houston, TX - 2013 to Present

Houston, TX 2013 - Present

Packaging and Containers Company

The company is a world leader in industrial packaging products and services. Greif produces steel, plastic,

fibre, flexible, corrugated and multiwall containers, container board and packaging accessories for a wide

range of industries.

Operational Excellence Manager, North America

Report to Director and Vice President of Operations for North America. Develop a healthy and effective results-

oriented culture of continuous improvement in plants. Coach and develop plant managers on Organizational

Performance Management. Utilize lean manufacturing principles to drive continuous improvement across

the facilities in North America. Manage the annual plant diagnostic process with plant managers to identify

performance gaps, prioritize opportunities, and establish action items. Lead regional kaizen events to build

capability in the plant leadership teams. Facilitate quarterly Centre of Excellence training.

• Directed 7 major manufacturing facilities in driving lean and continuous improvement initiatives resulting in

$1.9M in annual savings for fiscal year.

• $2.7M in annual savings by 24% changeover time reduction through regional SMED event on Steel main

lines.

• Led regional Kaizen event that reduced non-fundamental scrap 2.6% resulting in $870K in annual savings

across 4 large steel drum facilities.

• Drove implementation of Autonomous and Preventive Maintenance program in 13 steel manufacturing plants

resulting in 40% breakdown reduction, 11% OEE improvement, and $1.7M in savings.

Bounty Viper Operations Manager / Supply Chain Improvement Consultant

PROCTER & GAMBLE - 2012 to 2013

Manage overall business P&L and result tracking systems for organization of 240 employees and 10 direct

reports. Develop Business Master Plan with full responsibility for Budgeting and Forecasting. Coach and

develop team leaders, machine leaders and department leaders to achieve benchmark Production, Quality,

Cost, Delivery, Safety, Morale (PQCDSM) results.

• Reduced M&R budget for 6 departments 45% ($1.2M savings) through execution of Work, Plan & Scheduling.

• Decreased breakdowns in business 67% ($1.05M savings) through execution of AM and PM systems.

• Increased production 19% ($700K savings) through execution of Run-to-Target and Daily Management

Systems.

• Increased Make-Pack-Ship (MPS) 9% through execution of RCO systems (Best-in-Class).

• Reduced business PPMs from 15,000 PPMs to <100 PPMs through quality system execution.

PROCTER & GAMBLE - Albany, GA - 2008 to 2013

Paper Products Company

Charmin Ultra Strong Operations Department Manager

PROCTER & GAMBLE - 2010 to 2012

Oversaw operating budget and forecast for 3 departments with 90 employees and 6 direct reports. Accountable

for department staffing and performance assessment. Developed robust systems for SAP, autonomous and

preventative maintenance, and Loss Analysis. Coached machine and team leaders on Unified Problem Solving

tools for technical losses.

• Improved Process Reliability of converter lines from 56% to 78% within 8 months resulting in $458K savings

(Best in Category Results).

• Drove cultural change through safety awareness program and improved safety from 1 injury / quarter to

maintaining a 2-year injury free environment (Best in Site).

• Reduced converter stops from 43 stops / shift to 15 stops / shift (65%) through Focused Improvement projects

and execution of manufacturing base systems (Category Benchmark).

• Reduced Quality Incidents from 16 QIs / year to 3 QIs / year (81%) through Root Cause Analysis and

implementation of countermeasures.

Site Quality Assurance Engineer

PROCTER & GAMBLE - 2009 to 2010

Reported to Director of Quality and Plant Manager. Improved overall Quality Assurance capability across

site through creation and deployment of Quality Assurance Training. Led site improvement effort utilizing six

sigma methodologies. Coached and developed site quality leaders (Process Engineers and Quality Functional

Leaders). Drove Multi-Cause Analysis for all site quality incidents. Conducted quarterly Quality Control audits.

• Led Multi-Cause Analysis in organization and implemented countermeasures which reduced site quality

incident rate 40% and parts per million defects 64%.

• Reduced Consumer Comments 41% through utilization of problem solving tools like Cause & Effect Analysis.

Process Engineer / Project Engineer

PROCTER & GAMBLE - 2008 to 2009

Led initiative and continuous improvement projects for site. Managed and updated GSUM tracker for quality

improvement projects. Improved quality across site through Quality Assurance systems, EO's and IWS

methodologies. Facilitated vendor visits to determine product and equipment specifications.

• Facilitated SMED event to reduce average changeover time 41% resulting in $280K savings.

• Led implementation of Preventive Maintenance program which reduced Clean & Inspect time for all converters

65%.

• Drove 100% implementation of Run-to-Target Centerlines for critical equipment within 3 months.

Quality Control Leader

PAI INC - Antioch, TN - 2007 to 2008

Developed quality SOPs and quality training material. Led quality onboarding training for new employees.

Calibrate testing equipment to ensure accuracy. Tracked quality key performance indicators. Maintained

records of all ISO required documentation. Facilitated investigations regarding client complains and failures.

Audited corrective actions implemented for compliance.

• Reduced quality incidents 55% and reduced repeat QIs 90% through implementation of counter measures.

• Established SOPs which reduced defects 31%.

Quality Assurance / Quality Engineer Co-op

TOYOTA MOTOR MANUFACTURING NORTH AMERICA - Princeton, IN - 2006 to 2006

Design manufacturing processes to meet quality standards. Facilitate implementation of common production

quality processes and ISO requirements. Analyze existing operations and propose improvements. Establish

operation methods and work standards using various measurement techniques.

• Improved defect detection 64% through standard work implementation on assembly line.

• Drove platform installation project which eliminated awkward posture ergonomic issues plant-wide.

• Coordinated vendor site audits and root-cause investigations for defective parts.

Quality Assurance Supervisor

SABEREX GROUP - Nashville, TN - 2005 to 2006

Worked with product development engineers in developing specifications and test methods. Reviewed and

provided disposition for non-conforming product. Conducted 100% safety inspections around ESD areas on

the production floor. Created shipping electronic work orders and ensured goods were delivered on time.

Provided SMT quality support on production line to ensure proper product assembly.

• Eliminated rework for missing parts (No. 1 customer complaint) by implementing poka-yoke and integrating

visual standards for 100% quality inspection stations. Rework elimination resulted in $110K in savings.

EDUCATION

Bachelor of Science in Industrial Engineering

Tennessee State University - Nashville, TN

Institute of Industrial Engineers

ADDITIONAL INFORMATION

Core Competencies

- Lean Six Sigma - Project Management

- Continuous Improvement - ISO 9000, ISO 14000

- Business Forecasting - Total Quality Mgmt.

- GMP - Total Productive Maintenance

- Risk & Crisis Management - Change Management

- High Performance Org. - Creating Highly Effective Teams

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