Manager Maintenance

Douglas R. Malcolm III

***** ************ ********** ********, ** 48094 586-***-**** *********@*******.***

QUALIFICATIONS

Operations Executive offering over 20 years experience designing and implementing corporate manufacturing systems utilizing a mixed bag of expertise

RELEVANT EXPERTISE

World Class Manufacturing

Kaizen Activities

FMEA

Lean Manufacturing

Business Planning

New Business Generation

HS&E

Project Management

Six Sigma

People Development

Microsoft Office tools

Finance

Stamping

Line Balancing

Welding

Assembly Operations

Manufacturing

Leadership

Strategic Relationships

PROFESSIONAL SYNOPSIS (relevance)

E&E Manufacturing

Lean Manager – March 2015 – September 2015

Develop and implement a culture of continuous improvement for all 4 Plymouth, MI plants

Reduced Run To Run time by 70%, going from an average Die Change over of 60 minutes to and average of 16 minutes on 600 ton and 800 ton progressive press class

Co-Authored revised E&E Manufacturing Systems Employee manual.

Developed alternate Shaker Chute scrap system to accommodate heavily sorted scrap contract

Developed multiple Lean Manufacturing training systems for continuous colleague education. Including:

Kaizen utilizing PDCA

Human Error Root Cause Analysis

5S

Equipment FMEA

Autonomous Maintenance

Professional Maintenance

Early Equipment Management

Focused Improvement

Projects:

Identify current state map for die repair. KPIs:

oTurn Around Time

oStandard Work Instructions

oWorkplace Organization

oMaterial Handling

oIdentify part travel (spaghetti diagrams)

oControl WIP

oDesign and implement Kanban

Welding

Improve cycle times

Workplace Organization

Webasto Roof Systems

Lean Manager - March 2014 – January 2015

Implemented Webasto Production System (WPS)

Responsible for Lean Manufacturing efforts at 4 facilities including Assembly and Stamping

Developed Standard Work Instructions for Die Change Over Reducing Run to Run by 30%

Implemented a 5s program for Workplace Organization

Chrysler Group LLC., August 2011 to Present

Warren Stamping Plant –

WCM Specialist – May 2013 – December 2013

Work with various Business Unit Leaders to improve Press Line OEE

Work hand in hand with WCM Pillar leads

Focused Improvement

Autonomous Maintenance

People Development

oDeveloped Standard Operating Procedures for EOL Racking

oUtilized TWTTP to develop One Point Lessons

Workplace Organization

Preventive/predictive Maintenance

Die set Manager – January 2012 – May 2013

Utilizing a team of 17 Union members, Mr. Malcolm ensures dies are navigated throughout the plant within appropriate time intervals for continuous production of 11 press lines and 3 progressive presses.

Coordinate production schedules with press line leaders

Work closely with Die Shop to ensure proper maintenance of dies

Utilize WCM/Kaizen activities to improve Die Set

o25% reduction in staging time of dies (2 hours too 1.5 hours)

oincreased die movements from average of 13 per shift to 18

oDeveloping Die Set Training materials for the training of new die setters

Large Press Unit Leader – November 2011 – January 2012

Coordinated with team of die makers, toolmakers, end of line workers material handling and die setters to ensure continuous flow of 4 large presses.

Co-developed process to ensure timely quality inspection of parts

oIncreased probability of catching quality defect at end of line by 75%

oDeveloped a team end of line workers that were highly skilled in catching quality defects on product

oFewer line stoppages

Developed Autonomous Maintenance strategy for 2nd shift line 15

Implemented safety standards according to WCM

oNear misses

oUpdated safety board

oSubmitted work orders based on safety needs

Progressive Press Unit Leader

Coordinated with team of die makers, toolmakers, end of line workers material handling and die setters to ensure continuous flow of 3 progressive presses.

Implemented quick kaizen process with team members

Co-developed Autonomous Maintenance strategy for Press 3

Championed Safety board

Identify safety concerns in area

Conducted Job Safety Risk Analysis

DRM TECHNOLOGIES, December 1994 – September 2005

Vice President of Operations 2002-September 2005

Oversees all P&L initiatives as well as the development of corporate business plans. Supervises all internal programs, including R&M coaching, R&M training, R&M advocacy, customized training, new business generation, and new business models and concepts.

Projects of Note:

oGerdau Ameristeel – Whitby Ontario – Defining and developing an equipment maintenance strategy using a combination of Preventive and Predictive Maintenance techniques.

oTower Automotive – Madison Business Unit – Madison, Mississippi –

Defining and developing an equipment maintenance strategy for critical operating components. Identifying when maintenance should be done with the goal of reducing preventive maintenance actions while increasing stakeholder value

oFord Motor P221/Heritage Body and Structures – Manages DRM R&M coaches to ensure R&M project deliverables are met. Duties include managing budgets, evaluation of deliverables, timing schedules, and point of contacts.

oFord Motor D219/258 – Stamping Business Unit – Oversees the DRM R&M coach, including FPS audits, setting up data collection systems, lean manufacturing support, new plant equipment acquisition assistance.

Program Manager 2000-2002

Managed all projects assigned by the president. Was program manager in charge of 6 persons responsible for R&M coaching for all 27 North American Stamping and Assembly plants for Ford Motor. Resided as supplier lead for the rewriting of the Ford Motor Training manual.

Developed Lean structure for plastic injection molding company. Identified areas and process that could be eliminated or reduced. Evaluated inventory of finished products and raw materials.

Plant Coach/Instructor 1996-2000

Coordinated training for Ford plants. Assisted in the development of Ford FTPM R&M specifications. Developed and assisted in the development of ten DRM off-the-shelf training courses. Trained over 3,500 Ford and supplier base personnel in DRM courses.

Database Developer/Data Entry 1994-1996

Developed an MS Access DB for Ford Motor Global paint, which tracked all piping within a plant’s paint shop. Developed an MS Access DB that analyzed the various activities of the plumber/pipe-fitter skilled trade and determined the validity of tasks.

JPMorgan Chase Bank, NA; February 2006 – Present

Personal Banker

As a personal banker, Mr. Malcolm provides retail bank services to existing and new clients. Using a toolbox of retail products, the banker’s main focus is two fold. The first is to strengthen relations with existing customers, ensuring that every financial need is addressed. Second, acquire new clients. To accomplish this Mr. Malcolm sits with the prospective client and uncovers the existing financial situation. Next, it is then necessary to determine, jointly with the customer, where the customer wishes to be in what time frame. Mr. Malcolm then recommends the best bank retail products for the prospects.

Bankers Life and Casualty Company, September 2005 – January 2006

Sales Representative

Provide clientele with a wide range of life and health products from standard guaranteed life insurance to complex combined long term care policies with home health care riders. Also provides means of providing for a financially stable future, by using our products including life, health and annuities.

Education: BS in Administration with a focus on Industrial Operations Management; Central Michigan University ; GPA: 4.00 expected completion Fall 2016

Certifications

MTM-UAS –MTM Association May 2014 – May 2016

Skills:

Standard Microsoft tools (Word, Excel, Power Point, Access, Outlook), can read drawings.

Volunteer Work:

Rome Jr Bulldog Football Team Coach (OMYFA Football League)

For the past 5 years, Mr. Malcolm has volunteered his time to Romeo’s youth. As a football coach, he teaches boys to:

Be responsible

Be Respectful

Be a contributing member of the community

Become the best football player he can be

The goal of the Jr. Bulldog program, apart from winning games and competitions, is aiding parents in teaching their children to become well rounded young men and women

References

Available on request

Contact this candidate