Plant/General Manager

SHAWN P. STAPLES

***** ******** **** – South Bend, IN 46635

574-***-**** (Mobile)

**********@*********.***

QUALIFICATIONS PROFILE:

Highly accomplished Business/Operations/Lean Professional with extensive experience in multiple industries, with an emphasis on P & L, Operations Management and Lean Manufacturing systems.

Trained and Educated in Toyota Production System (TPS) (Lean Manufacturing)

Track record of improving facilities and developing employees

Solid record of achievements, including streamlining operations and instituting improvements

Outstanding problem-solving/troubleshooting skills; able to address and resolve manufacturing, admin issues and bottlenecks

Excellent leadership, management and motivation acumen; adept in leading teams to achieve goals and complete tasks on-time; within or under budget

Highly effective communication, facilitation and training skills

PROFESSIONAL EXPERIENCE:

SUPREME CORP INC – Goshen, IN - July 2013 - Present

General Manager/Sales Manager – Bus Division

Assumed responsibility for a division of 203 employees that was losing $500K per month and within 6 months improved to losing $15K per month. Sold off part of the division

Instituted cost saving initiatives with suppliers and reduced Inventory by over $1.5M

Keyed on 6 KBI’s – Safety, Quality, Delivery, Cost, Empowerment and Continuous Improvement

Implemented Lean Principles of JIT, Right Sizing, FIFO, 5S, VSM, Gemba, Point of Use, Std. Work

VALMONT INDUSTRIES INC, Plymouth, IN (Responsible for 12 total sites) - February 2009 – July 2013

Divisional Director (Lean, Operations, Safety, Quality)

World Class Techniques, Focused on Key KBI’s-Safety, Quality, Delivery, Cost, Empowerment and CI

Conducted multiple hands on kaizen workshops that focused on process efficiency and quality improvement utilizing 5S, Value Stream Mapping, Standard Work & Visual Factory.

Taught/Trained - Plant Scheduling of low volume high mix production

Worked with all phases of machining, welding, fabrication, CNC, assembly

Develop Plant Lean Leaders on Lean Manufacturing principles by coaching them in hands on VSM and Kaizen workshops. Primary focus to drive improvements utilizing objectives developed from each plants AOP (Annual Operating Plan).

Coached and trained General Managers through X-Matrix planning to achieve their AOP objectives

General Manager (Plymouth, IN/Salem, OR) - Promoted to Divisional Director

Consolidated Plymouth, IN from five facilities into two - sales of $120M annually

Came in under budget on a plant expansion project - over $700K

Led numerous Kaizen Events to improve Admin and Manufacturing Processes identified through Value Stream Mapping

Implemented Lean Principles and engaged all employees to focus on Customer Service, Continuous Improvement and Waste Elimination – Kanbans, JIT, 5S, Heijunka, 3P process

Worked on Core Competencies of Welding, Fabricating, Quality and Engineering

Plymouth, IN; 2010 losing $4.5M to 2011 breaking even and 2012 to a $2.4 M profit

Salem, OR; 2010 losing $500K to 2011 $100K profit and 2012 to $1.2 M profit

GLAVAL BUS, Division of Forest River Inc., - Elkhart, IN - October 2007 – November 2008

Director of Manufacturing

Reduced labor by 16%

Reduced units in the yard by more than 58%, which freed up over $1M in cash

Improved on time delivery by 10% by improving Scheduling, Purchasing and Material Reduction

Improved quality by implementing stricter quality standards – Received Quality Improvement Award

Implemented and certified in ISO 9001:2000

COACHMEN INDUSTRIES INC., - Middlebury, IN - March 2006 – October 2007

General Manager/Division Director of Lean

General Manager of 190 employee plant

Coached and implemented Lean in 3 facilities

Implemented Quality and Lean Metrics – Quality, Delivery, Safety and Cost, Empowerment, CI

Reduced inventory by over 50%, focused on Scheduling, Quality and Efficiencies

Converted two facilities into one overall facility using the 3P process

PARKER HANNIFIN CORP, Tech Seal Division - Goshen, IN – Tier One Supplier - September 2001 – March 2006 Plant Lean Manager/Six Sigma Black Belt

Led and/or participated in 175 Kaizens over six facilities, with over $2M in annual savings

Implemented lean cost reduction suggestion program

Six Sigma Black Belt Project which included a Design for Six Sigma implementing new equipment

DAMAN PRODUCTS INC. - Mishawaka, IN - January 2001 – September 2001

Cell Leader

Developed self-directed work teams in four different work cells – heavy machining in CNC

Implemented JIT, 5S, Kanbans and one piece flow

LEAR CORPORATION INC. - Bourbon, IN – Tier One Supplier - August 2000 – January 2001

Plant Superintendent

Improved efficiencies and reduced change over time by 30%., fabrication and heavy presses

Responsible for 5 supervisors and 115 union hourly employees

GOSHEN RUBBER a division of WYNN’S PRECISION – Goshen, IN – Tier One Supplier - July 1995 – August 2000

Plant Superintendent

Improved efficiencies, reduced OSHA recordables, improved safety and quality

Responsible for 3 shifts, 10 supervisors, and 150 union hourly employees.

Implemented and certified in QS9000

Consolidated three facilities into one, implementing work cells and improved throughput

ACCRA PAC GROUP INC. - Elkhart, IN - September 1992 – July 1995

Self Directed Work Team Coordinator/Production Manger

Developed and implemented Self Directed Work Teams (SDWT) in consumable products.

Designed the SDWT (Self Directed Work Teams) production lines

SPECIAL SKILLS: Leadership and decision making, strong negotiations skills, dealing with union issues, excellent communication skills. Microsoft Word, Excel, Power Point, Access

EDUCATION: Goshen College, Goshen, IN - Bachelor of Science Degree in Organizational Management – May 2009

TRAINING: Six Sigma Black Belt Certified

TS 16949/ISO14001 Management Representative, ISO Auditor

Value Stream Mapping/Mixed Model Value Stream Mapping

Lean Training in TPS taught by Toyota Sensei

Total Quality Management (T.Q.M.)

Total Productive Maintenance (T.P.M.)

FMEA (Failure Mode and Effects Analysis) Training – DuPont

OSHA and Ergonomic Training

APICS Classes

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