Plant/Site Manager of a leading manufacturer of quality welded conveyor pulleys and associated equipment. Responsible for all operations and financials of the Conveyor Components manufacturing plant. Posted two best top line financial years while improving productivity 18 points over the last 4 years. Developed and implemented a strategy to in-source long lead time components for large engineered pulleys, reducing cycle time by months and cost by 40%. Moved from fourth to second in sales among Conveyor Equipment Manufacturer Association companies. Achieved the lowest OSHA recordable injury rate in the previous 7 years.
Baldor A Member of the ABB Group, Clio, South Carolina 2006 – 2015
Manufacturer of welded, machined and assembled conveyor equipment, annual sales $25M
Conveyor Components Plant/Site Manager (2011 – 2015)
Site Manager responsible for all operations; Safety, Quality, Customer Service, Financial performance.
Lead and direct plant senior management team (Quality, Supply Chain, Finance, Human Resources, Engineering, Safety and Environmental).
Own the Safety and Environmental programs ensure employee safety and compliance with all state and federal regulations.
Prepare annual financial operating plan using standard base accounting.
Drive quality from design through delivery.
Improve process to meet customer delivery requirements
Promote and sustain lean improvements, drive continuous improvement.
Maintain accurate inventory control and levels.
2015 Safety achieved best plant OSHA recordable rate in last 7 years, reduced rate from 2.7 to .94 continuing a 4 year trend of year over year improvements.
Managed transition to large engineered pulley plant by reducing stock product offering, lowering headcount and developing future state transition plan including a 4% reduction in cost of goods produced.
Implemented new work schedules and supervisory responsibilities resulting in improved customer service metrics posting an on time of 95% and fill rate consistently above 95% throughout 2015; a 20% improvement.
Improved cycle times by 50% and reduced material cost by 40% on large engineered product by insourcing heavy plate rolling and large diameter turning.
Posted two best top line years in plant history and 3 of 4 years posted record low operating expense ratios.
Completed Six Sigma Black Belt project and received certification. Project delivered reductions of 74% in scrap, 53% in rework, and 69% in first pass rejections and $134K in annual savings.
Lead transition team implementing Baldor Unified System (SAP) and Shop Floor Display production management system. Clio was the first custom product plant converted; the Core team praised Clio’s preparedness and team work.
Instrumental in developing a product configurator used by the sales team that produces quotations, Bills of Material and Routings for pulley assemblies. Implemented a capital improvement plan of over $4.5M since 2011 reducing outsource by over $500K per year and lead times on project pulleys by 50%.
Manufacturing Engineering/CI-Lean/Maintenance Manager (2006 – 2011)
Manage Engineering staff and the capital process including identifying equipment improvement/replacement projects, developing financial business case, equipment specification/selection, and installation and commissioning of equipment for production.
Develop expense and capital budgets for Production, Lean and Maintenance.
Update standards and BOM’s to accurately reflect productivity and process improvements.
Manage the Continuous Improvement program, identify and implement Lean initiatives.
Manage Maintenance Team and implement Preventative Maintenance program
Continuously improve welding practices, quality, productivity and reduce cost.
Develop Welding Procedure Specifications, qualify procedures, train and certify welders to AWS D1.1 and AWS B2.1.
Direct, mentor and develop the Engineering team of 4, Lean engineer, Maintenance Supervisor and 4 technicians.
Implemented 1 piece rim rolling, eliminating one weld seam and reducing scrap by 40% while maintaining quality.
Responsible for the concept, machine design and implementation of the hydroforming process for single piece rims up to 18” Dia. X 66” FW.
Implemented A-Minus manufacturing value stream, Lean certified process in February 09, reduced manpower requirements from 16 to 3 to manufacture CEMA pulleys 18” & under.
Implemented welding certification training program providing hands on and classroom training on welding processes, equipment, consumables and process variables.
Developed pulley quoting program reducing cycle time on quotes from days to hours.
Recognized by sales and marketing as technical resource for solving customer quality and delivery issues.
Developed new manufacturing capabilities for stainless steel pulleys and fabricated items such as swing bases, pump bases and telescoping take up frames resulting in over $1M increase in top line.
Implemented certified ASNT Non-Destructive Testing program to meet customer specifications and eliminate outsource cost.
Created a state certified maintenance apprenticeship program to develop technicians from direct labor employee pool
Eastman Kodak Company, Rochester, New York 1979 to 2006
Manufacturer of Chemicals, Film and Hardware Kodak Park facility
Welding Engineer / QAM Boiler & Pressure Vessel Program) (2002 to 2006)
Lead Welding team consisting of 50 welders and fitters and 2 welding inspectors.
Manage ASME & NBIC Quality Control Code program for fabrication, repairs and alterations of boilers and pressure vessels.
Work with Kodak divisions, U.S. and Canadian Sites to schedule inspections and repairs of Boilers, Equipment and Machinery.
Supervise the Quality Control and Welding Technical Team responsible for in-service inspections and quality control of repairs or alterations for seven coal fired high pressure power boilers and over 600 pressure vessels and regulated chemical process tanks.
Chief Inspector of the NBIC Owner User Inspector Program responsible for preparing budgets, establishing inspection schedules, coordinating with customer departments, and maintaining database and record retention system.
Perform shop audits and in-process inspections of vendors manufacturing ASME Section VIII Division 1 Code equipment to be installed at our plants worldwide.
Developed and implemented a risk/history based inspection matrix for evaluating inspection scope and frequency. This resulted in performing more comprehensive inspections less frequently saving over $100,000 per year.
Evaluated ASME Section VIII Code manufacturers in Shanghai, China selecting vendor for fabrication of over 40 ASME Section VIII Division 1 Code vessels for fast paced project.
Negotiated contract with third party inspection agency to perform daily inspections of fabrication work performed by manufacturer in Shanghai, China.
Lead business team effort to evaluate actual cost of operating in a large corporate structure developing individual business plans for each trade in the Construction Division.
Facilities Engineer (Welding Engineer) (2002 to 2005)
Utilize my NBIC and New York State Owner/User Commission as an Inspector of boilers and pressure vessels to perform Code inspections of repairs and alterations.
Responsible for welding quality control of plant infrastructure equipment including steam and electric generation, distribution pipelines for steam, water and chemicals.
Develop, upgrade and maintain ASME Section IX and AWS Welding Procedures for SMAW, GTAW, GMAW and FCAW of Nickel Alloys, Aluminum, Titanium, Carbon Steels and Alloy Steels with and without heat treatment.
Recognized welding and inspection expert for Kodak worldwide.
Developed and qualified to ASME Section IX an automatic tube welding procedure for joining AL6XN (6% molybdenum alloy) using a filler ring made from Inconel 625 tubing. This method reduced the cost by $8 to $12 per weld joint.
EDUCATION, TRAINING, AND CERTIFICATIONS:
AAS Mechanical Technology, Monroe Community College, Rochester, NY
Core technical courses completed toward B.S. Welding Engineering
American Welding Society Senior Certified Welding Inspector
Baldor Certified Six Sigma Black Belt and Lean Master
Baldor NDE Level III. UT, PT, MT, VT
ASNT - ACCP Level II Visual Testing with Pressure Equipment endorsement
Metallurgy of Welding – Ohio State University, College of Welding
Boiler & Pressure Vessel Inspection – Ivy Tech State College, Terra Haute, IN
Failures, Failure Prevention & Repair of Pressure Vessels ASME
Fundamentals of Corrosion and its Control – LeQue Center for Corrosion Technology
Metallurgy of Welding and Joining – Materials Engineering Institute of ASM International
Principles of Failure Analysis – Materials Engineering Institute of ASM International
Lean Flex Flow Master Training