Maintenance Manager

Michael Cleppe

**** ******** ***** 563-***-****

Bettendorf, Iowa 52722 *******************@*******.***

Manager, Supervisor, Operations, Maintenance, Lean Manufacturing

More than 20 years of successful experience in leadership at all levels of Manufacturing and Operations

Performance Profile/Performance Summary

A results oriented leader that involves/engages all stakeholders and team members in continuous improvement of critical processes. Utilizes tools such as; Lean Manufacturing, Toyota Production Systems, Root Cause Problem Solving, OEE, Shop Floor Metrics, Six Sigma, Total Productive and Reliability Centered Maintenance tools for improvement in a team environment. Quickly identifies and deploys the appropriate shop floor metrics that clearly connect all stakeholders with the strategic business goals. Transformative Leader with uncompromising core values in safety, environment and people. Experienced with Quality Systems such as; ISO, AS9100, NADCAP, etc.

Core Competencies

>Operations Management

>Maintenance Management

>Six Sigma Greenbelt/SPC

>Toyota Production System

>Lean Manufacturing, 5S

>Root Cause Problem Solving

>Total Productive Maintenance

>Reliability Centered Maintenance

>Continuous Process Improvement

>Team Building

>Relentless Innovation

>Standard Work

>Daily Management Boards

>OEE

>Training & Development

>Welding/Fabrication

>Machine Shop Management

>Project Management

>Strategic Planning

>Planning/Scheduling

>Quoting

>Metals/Materials

>Quality Systems

>EHS

>Labor Relations

>Collective Bargaining

>P&L Management

>Budgets

>ISO 9001/2008

>AS 9100C

>Recruiting

>Performance Evaluation

>Sales

>Marketing

>Customer Service

>Metals Part Making

Professional Experience: (note: 2004 through current all employment with Allegheny Technologies Inc.)

Current: Facilities, Maintenance, Security, and Paint Manager

Responsible for design, training and deployment of Maintenance, Cost Reduction, and Process Improvement utilizing tools such as Reliability Centered Maintenance (RCM), Total Productive Maintenance (TPM), Toyota Production System (TPS), Overall Equipment Effectiveness (OEE), Lean Manufacturing, 5S, Etc. Provide leadership for ~180 employees managing a budget >$40M.

March 2012-June 2013: promoted to President ATI Engineered Products (ATI)

Responsible for all aspects of the EP Group including Casting Service, Portland Forge, Precision Finishing, and Fabricated Components. Define and deploy on overall profitable growth strategy for the above companies. Significant work developing new markets, customers, product development, etc.

September 2010-March 2012: V.P. Engineered Products & G.M. ATI Fabricated Components (ATI)

Lead for a new start up business (green field site) for ATI in the Chicago area. Secured location, installed infrastructure, building services, purchased & installed all equipment, hired all the hourly and salaried staffing, developed work flow, information flow, and Business Systems. Worked with ATI Defense Team & other ATI Companies to secure customers. Achieved business start-up in ~15 months. Define and deploy on overall profitable growth strategy for the above companies. Significant work developing new markets, customers, product development, etc.

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March 2007 to September 2010: V.P. Operations Engineered Products (ATI)

Responsible for 3 businesses: Casting Service, Portland Forge, and Rome Metals. The Casting business produces very large grey and ductile iron castings from 2,000-100,000 pounds for the “wind energy”, transportation, and oil/gas markets. The Forging business produces steel forgings from 20-300 pounds for the automotive/truck, transportation, mechanical power transmission, and farm machinery markets. Rome Metals is a semi-finishing/finishing process for stainless steel, titanium, zirconium, and nickel alloy materials from .500” – 16” thick as well as various shapes/sizes. Full P&L responsibility, sales/marketing, safety, quality, customer service, etc. for all ~800 employees. Career has been primarily in the metals industry and manufacturing stainless steel, titanium, and aluminum sheet, plate, and coil products in all specifications. Define and deploy on overall profitable growth strategy for the above companies. Significant work developing new markets, customers, product development, etc.

March 2004 to March 2007: General Manager Allegheny Ludlum Business Systems (ATI)

In March of 2004 started as a full-time consultant to Allegheny Tech. Inc. to provide experience in deploying Lean Manufacturing/Toyota Production System and Total Productive Maintenance (TPM), Reliability Centered Maintenance (RCM), Overall Equipment Effectiveness (OEE) across the corporation. After 3 months accepted the full time position of General Manager ATIBS, covering 14 different locations, leading the deployment of these tools and our Business System. Allegheny Ludlum is a specialty steel and stainless plate and sheet manufacturer. Facility sizes range from 1200 employees to 150 employees.

Last six years of manufacturing experience has been focused on deploying the Toyota Production System(TPS), Lean Manufacturing, Total Productive Maintenance(TPM), Reliability Centered Maintenance(RCM), Hoshin Strategic and Tactical Deployment Strategy, Management By Objectives, Etc. in complex manufacturing environments. During current employment completed Six Sigma Green Belt training from our certified Six Sigma trainer. Our deployment @ ATI/ALC has included implementing Kaizens, High Focus Cross Functional Teams, TPM, RCM, OEE, Quality Systems, and Pull Manufacturing

Systems, and employee involvement/engagement, etc. Achievements include: improving throughput (OEE)

by ~15 -25%, developed and implemented A3 strategic planning tools to simplify and reduce flow time and inventory by ~25%, and deploying a Kanban pull system across a complex flow path, identifying Quality/Yield losses and reducing losses by 10% with a targeted improvement of an additional 20%.

(Several documented examples and results provided at request).

References provided upon request.

Alcoa Mill Products, Riverdale, IA 1973 – March 2004

Sheet Mill Manager 2002 –March 2004

Led Sheet Mill products manufacturing for the Davenport Works facility. Provided leadership for approximately 600 hourly production employees, 70 maintenance hourly employees, 80 production management and staff personnel, and 15 maintenance and staff personnel. Deployed TPS, TPM, Hoshin Strategy, RCM OEE, and Quality Systems strategies with internal plant customers and strategic external customers. Worked with strategic customers on connecting and integrating supply chains to reduce costs of products sold.

Maintenance Manager 2000 - 2002

Supervise crafts, management and staff personnel. Crafts supervision included general mechanics, welders, electricians, carpenters, painters, roll grinders, machinists, fabricators, equipment operators and support staff of engineers and technicians. Included directing of large machine shop with ~75 machinists and fabricators, CNC and conventional machining equipment, large weld shop fabrications, etc. Led plant wide contracting out committee and plant resource for contractor activities. Deployed TPS, TPM, Hoshin, RCM strategies with internal plant customers and strategic external customers.

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Coil Sheet Manufacturing Manager 1999 - 2000

Led Coil Sheet business supervising 230 hourly production and 25 management and staff personnel. Coil Sheet business plan included more than 25 - 30 million finish pounds of coil heat-treated and non-heat-treated products each month. Improved delivery performance to customers, product yield and recovery, variable costs, through put, and over- all safety /injury performance.

Deployed TPS, TPM, Hoshin, RCM strategies with internal plant customers and strategic external customers.

Cold Rolling Manufacturing Manager 1996 - 1999

Supervised 140 production, hourly, and 15 management and staff personnel. Planned and scheduled 4 Cold Mills running multiple passes on aluminum coil products including automotive, lithographic, aerospace skin sheet, tread sheet, common alloy sheet, and miscellaneous coil sheet products. Achieved more than 45 million passed pounds of high quality product each month. Improved overall through put customer delivery performance, 35% flow time improvement and associated inventory reductions, and improved recovery / yield by 20%. Deployed TPS, TPM, Hoshin, RCM strategies with internal plant customers and strategic external customers.

Mechanical Maintenance Shops and Construction Superintendent 1992 - 1996

Supervised more than 250 maintenance crafts people and approximately 65 management and support staff.

Maintenance of all plant utilities; water, steam, air, waste, recycling, overhead and gantry cranes, implementing ~ $25MM of Capital Projects with all skilled crafts, coordinated outside contractor crafts with plant craft resources, etc. Directed large machine and fabrication shops with CNC and conventional machine shop equipment for repair and fabrication of parts and equipment. Utilized TPM and RCM tools.

Machine Shop General Supervisor 1990 - 1992

Supervised a large machine shop with 60 machinists and 15 shop welders.

Maintenance and Engineering Planning / Scheduling Supervisor 1988 - 1990

Hot Rolling Maintenance and General Supervisor 1985 - 1988

Safety Coordinator 1983 - 1985

First Line Supervisor, Maintenance 1980 - 1983

Hourly Employee 1973 - 1980

Education and Training:

BA in Business Administration from Franciscan University (Clinton, Iowa).

Training: Working with People

Leadership Skills, Teamwork, Communications/Listening Skills, Performance Assessment, 360 Degree Feedback, Leadership Development, Tuff Stuff Leadership, Diversity in the Workplace, Negotiations.

Training: Operations Continuous Improvement:

Lean, Toyota Production System, Total Productive Maintenance, Reliability Centered Maintenance, Overall Equipment Effectiveness (OEE), Root Cause Problem Solving, FMEA, Six Sigma Greenbelt, SPC, Quality Systems, Safety Business Strategy, Strategic Planning, Project Management.

Training: Technical

Department of Labor Apprenticeship, General Maintenance, Welding, Fabrication, Machining

Metallurgy; working with materials; forming, welding, heat treating, forging, casting, rolling, cutting, finishing, etc.

Materials: Aluminum, Carbon/Alloy Steels, Stainless Steel, Titanium, Iron, Exotic Metals, etc.

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