Manager Management
Resume:
DENNIS CALLAHAN
Fayetteville, North Carolina 28306
***********@*****.***
www.linkedin.com/in/callahand10
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MANUFACTURING MANAGEMENT / PRODUCTION LEADERSHIP
Continuous Improvement / Lean Manufacturing / Value Stream Management Skilled Manufacturing Manager with hands-on experience combining productivity, process improvement, lean manu- facturing and quality supervision. Demonstrated success implementing continuous improvement initiatives utilizing six sigma methodologies. Extensive experience implementing cost reduction and resource re-allocation programs in high volume manufacturing environments. Excellent budget, direct-cost responsibilities. A proven record of leadership as both a facilitator and leader. B.S. Engineering, West Point Military Academy. EXPERIENCE
ELKAY MANUFACTURING COMPANY, Lumberton, NC 2011- October 2015 Manufacturer of stainless steel sinks for residential and commercial use. The largest stainless steel sink maker in the United States.
Manufacturing Manager
Manufacturing management and budgetary/cost responsibility for an $80 million facility, 3 shift operation employing 375 employees. Overall responsibility for manufacturing operations as well as managing supervisors, team leaders and production associates. Accountable for quality, lean initiatives, delivery, cost, key performance indicators, and safety. Provided direct and indirect leadership for 225 – 250 associates.
• Developed and communicated production plans, quality performance, and delivery performance.
• Managed and reported costs and champion process improvement and efficiency improvement activities.
• Defined and executed departmental staffing plans, provided coaching, and conducted performance appraisals and disciplinary actions as appropriate.
• Developed training programs to facilitate cross-training of manufacturing processes, quality checks and equipment set-up.
• Reduced scrap costs to under budget 7% in 2014 and 5% in 2015.
• Efficiency increased 0.9% from 2014 to 2015.
GOODYEAR TIRE & RUBBER COMPANY, Fayetteville, NC 2006 – 2011 Value Stream Manager/Area Manager
Provided leadership and systems improvements to efficiently operate production activities as well as provide support towards the continuous improve all processes. Accountable for streamlining production operations with 2 engineers by overseeing installation of 6 full-stage automated tire assembly machines from start-up to full production. Traveled to machine manufacturer during the machine building process of the 1st machine, and during the final run-off prior shipment to Goodyear.
• Molded a collaborative team of 6 supervisors and 180 unionized workers by providing safety and standardized training to maximize productivity and minimize downtime of 24/7 plant operations.
• Led and directed 50 shift employees in daily tire manufacturing operations, ensuring compliance to safety, policies, and procedures to achieve production schedules at the highest quality control.
• Monitor production activities and processes to prevent downtime due to issues such as raw materials shortage, ma- chine maintenance, and Parts Per Million (PPM) defect rate increase.
• Maintain continuous communication flow and interaction with shift supervisors, maintenance personnel, engineers, and business managers to implement scheduled/unscheduled changes.
• Manufacturing Management • Lean Manufacturing • Value Stream Management
• Cost Budget Management • Continuous Improvement • Safety Management
• Quality Management • 5S Coordinator, SPC, KanBan • ISO 9001, JIT
• Six Sigma Methodologies • Team Building/Leadership • TQM/TPM/Kaizen Callahan, Dennis page 2 of 2
WILSPEC TECHNOLOGIES, Oklahoma City, OK 2002 – 2006 Director of Manufacturing and Quality
Led all manufacturing activities and developed a global partnership with a leading manufacturer in China for a start-up company of HVAC components (primarily pressure switches and valves). Travel with company executives to China, facilitating their tour of the company owned/contracted manufacturing facility.
• Implemented Lean Manufacturing practices into the facility, reducing the average production cycle time by 25%, while succinctly eliminating process related defects for over 3 years.
• Masterminded and initiated ISO 9000 compliance quality systems and documentation, reducing the number of customers’ in-process rejects and field defects to less than 1% of PPM.
• Received multiple quality and supplier awards from major United States Original Equipment Manufacturers (OEM) for exceptional quality of workmanship and on-time delivery rates.
• Awarded major customer contracts over well established competitors, resulting in revenue growth from
$2 million to over $13 million in less than 2 years. COLLINS & AIKMAN, INC., Greenville, NC 2001 – 2002 Department Leader
Overall management for the production and lean manufacturing practices. Accountable for 70 associates.
• Implemented Total Productive Maintenance (TPM) in knitting and warping departments. In conjunction, developed a visual system on the floor that showed/told operators and maintenance when PM service was due on the equip- ment.
• Contributed to annual profits of $18 million by reducing waste, eliminating excess inventory, stocking only ade- quate supply of raw materials, and more efficiently managing storage. INDALEX ALUMINUM SOLUTIONS, INC., Winton, NC 2000 – 2001 Process Improvement Engineer (P.I.E. group)
Provided Lean Manufacturing training and lead Kaizen events.
• Generated annual savings of over $450,000 by reducing material and labor costs with improvements to production flow and schedules.
Carriage Carpets, Inc., Calhoun, GA 1999 – 2000
Department Leader
Texas Instruments, Inc., Versailles, KY 1988 – 1999 Manufacturing Superintendent/Marketing Specialist/Applications Engineer/Manufacturing Supervisor EDUCATION & TRAINING
Bachelor of Science in Engineering, United States Military Academy, West Point, NY Undergraduate Certificate in Project Management, Columbia Southern University, Orange Beach, AL U.S. Army - Captain (accountable for up to 140 enlisted and officers)
Occupational Safety Health Agency (OSHA) 10
8-D Problem-Solving Techniques (Ford Format)
Diversity Training / Situational Leadership
ISO-9000 Documentation Training
Team Leadership & Coaching
Total Productive Maintenance/Lean Manufacturing/5-S Training
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