Manager Manufacturing

GUSTAVE G. DYLLA

Sea Girt, NJ ***** • 732-***-**** • (H) 281-***-**** (C) • ************@*****.***

Operations/Plant Manager

Cost Reductions Product Development Manufacturing Management Process Optimization/Lean Manufacturing

Hands-on Operations Executive with over 25 years of process plastics manufacturing experience. I have successfully completed two manufacturing startups. I am a senior operating executive with a P&L responsibility for two custom rubber and urethane manufacturing facilities. I reengineered sales and maximized profitability in one company from sales of 2.2 million to 4.7 million within a two year period. Full accountability for all strategic and business planning, production control, recipe formulation, mixing, molding, scheduling, engineering, materials management, purchasing, inventory control, and accounting.

Management Profile

Worked in a Quality Control Program to maintain company’s 95% quality and on time delivery rating for all products manufactured.

Restructured cost structuring of Product Lines through in depth cost analysis of manufacturing processes and cycle times.

Developed Custom Urethane Formulations and Processes for Otis Elevator that outperformed our competitors and industry standards.

Setup and implemented two ERP Manufacturing and Accounting Software Systems.

Trouble shooter for all manufacturing processes improving margins and the bottom line

Reduced cycle costs in established $1,200,000 product line by 39%, through lean mfg.

Key Skills: Exceptional strong written and verbal communication skills. Highly personable and capable of working with other CEOs, family-controlled businesses, and corporate boards. Proficient in meeting tight deadlines and customer’s requirements.

Career Overview

Consultant in Manufacturing Operations 2014 to Present

Analyzes client companies’ cost, quoting, quality, and other processes and operational infrastructure to improve efficiency and profitability.

Evaluate, setup, and implement ERP manufacturing software systems.

Analyze companies ERP platforms for improvements in efficiency and profit margins.

Identify costing issues in estimating in regard to operations, materials, scrap rates, and work center efficiencies.

OSHA compliance, Right to Know, MSDS, labor relationships and customer /client practices.

Clients have included: Spinning Designs, SonRise Metals, Air Wolf, Adagio Teas, and Rubber & Silicone Products.

Precision Urethane & Machine Inc., Hempstead, TX 2013 – 2014

Operations Manager

This is a privately owned 60 employee (non-union) job-shop thermoset / polyurethane molding operation, running 1 shift, five to six days per week.

Hired to improve company’s estimating, job costing, cycle times, QC, manufacturing, scheduling, and other processes.

Increased company production efficiency from 59% to 91% in 9 months through department analysis in estimating, job costing, cycle time analysis, QC, and manufacturing processing. Evaluated the shop floor and made recommendations for meeting OSHA compliance and optimizing manufacturing processes.

Inherited a 30% turn-over rate with numerous OSHA violations.

Established new 1st Article Inspection procedures and guidelines for product lines.

Supervised a Team of five direct reports: Plant Manager, Urethane Manager, Shipping/Receiving Manager, CNC Manager, and Quality Manager.

Processes included: Polyurethane processing, spin casting, compression molding, transfer molding, injection molding, casting, and CNC machining.

Products included: Polyurethane rollers, urethane tubes, urethane pads, polyurethane bushings, urethane pipeline bushings, urethane pipeline products, polyurethane rings, urethane cable products, multi hardness products, polyurethane gears, urethane seals, polyurethane liners and urethane couplings used in the oil & gas industry..

Resigned due to inability to maneuver Ownership towards OSHA compliance.

Dylla Manufacturing Co. Inc., NJ

Owner/General Manager 2003 - 2013

Successfully established this start-up custom polyurethane manufacturing company venture through planning, staffing, and budgeting from concept to full-scale operations.

Operation ran 1 shift, 5 days per week, 5 non-union employees. Mainly consulting operation and prototype manufacturing.

Streamlined operating infrastructure replaced non-performing staff and introduced automation and performance improvement initiatives throughout the manufacturing organization.

Processes included: Polyurethane processing, compression molding, transfer molding, casting and CNC machining.

Products / Applications included: castings, machining, processing, joining processes, cutting & tool design, tools, machining systems, automation, jigs and fixtures and die & mold design.

Customers included: Otis Elevator, Thyssen Krupp Elevator, Schindler Elevator, Air Wolf, Magil Corp., Harper Cranes, Automatic Switch, Flow Smart, and ViaSystems.

Rubber & Silicone Products Co., Inc., Fairfield, NJ 1982 – 2003

GM/President

P & L responsibility, cost accounting, sales, contract negotiations and the day to day operations of the company.

Transitioned company from a paper system to a fully computerized integrated ERP manufacturing system.

Products included: Aircraft & aerospace specialties, automotive specialties, bumpers, bushings, diaphragms, electric caps & plugs, elevator specialties, gaskets, grommets, mallets, marine specialties, mountings, O-rings, oil well specialties, packing’s, pistons, pump valves, rings, seals, sheets, slab rubber, sheave liners, textile specialties, tires, valves, washers and wheels.

Customers included: Schindler Elevator, Global Elevator, Ingersoll Rand, IBM, DuPont, Otis Elevator, ASCO, Parker Hannifin, AT&T, Bell Atlantic, Curtiss Wright Flight Systems, Westinghouse, Dover Elevator, NASA, ViaSystems, Lentron Corp., Baxter Rubber, Minor Rubber and others.

Reported to Stock Holders.

Left company after company was sold.

COMPUTER SKILLS

Visual Manufacturing and Accounting, Shoptech Manufacturing and Accounting, Mas 90, Excel, Access, Word, Outlook, PowerPoint, UNIX, Windows XP Professional, Windows Vista Professional, Windows 7, Henning Visual Estitrack Software, Real World Accounting and Manufacturing, Crystal Reports

EDUCATION AND TRAINING

Drew University, Madison, NJ

Seton Hall University, South Orange, NJ

Cifas Medical School 1-1/2 years

PROFESSIONAL AFFILIATIONS

PMA - Polyurethane Manufacturer's Association

New Jersey Business and Industry Association

CERTIFICATIONS

Basic Rubber Compounding and Processing

Low Pressure Boiler License

LANGUAGES

English and Basic Spanish

http://www.linkedin.com/pub/gustave-dylla/20/a82/428

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