Manager Plant

THOMAS A. CHARNESKY MBA, BSIM

*** *** ***** **, ******, MI 48371 • 313-***-****

http://www.linkedin.com/in/thomascharnesky • **********@*******.***

EDUCATION

M.B.A. University of Detroit - Detroit, MI

B.S. Industrial Management, Lawrence Technological University - Southfield, MI

American Axle Lean Manufacturing Trainer Training: 5S, Quick Die Change, Toyota Production System,

Visual Control Systems, Standardized Work, Problem Solving, TPM, Mistake Proofing

PROFESSIONAL EXPERIENCE

UNIQUE FABRICATING, Auburn Hills, MI 2015-2016

A custom foam fabricator that produces engineered die cut and molded parts servicing multiple industries.

General Manager

Responsible for over 248 total union/non-union employees in the 200,000 sq. ft. facility that produces over 2000 different parts weekly. Established 5S, daily boardwalks, daily shipping shortage meetings, manpower planning linked to sales forecasts. Discovered inconsistencies in operating system and implemented processes to manage shortcomings.

Improved productivity by 17%, and on time delivery by 10%.

Created a daily production-reporting sheet that improved production deliverables and is used company wide.

BROSE NORTH AMERICA, New Boston, MI 2013-2014

A new plant startup with 260 non-union employees is a JIT provider of automotive door, seat and motor assemblies.

Logistics Director (Left in June due to change in business structure. Facility is now just assembly, no longer assembly & manufacturing as initially planned when accepting the job.)

Responsible for the implementation of material systems and personnel to manage the new 350,000 sq. ft. facility.

Strategized and executed a total logistics plan to improve production efficiencies by 12% and reduced material handling by 19%.

Obtained TS-16949 and ISO-14001 certifications.

FAURECIA NORTH AMERICA, Auburn Hills, MI 2011-2013

Staffed with 90 non-union employees, FNA is a full service supplier pilot plant of interior dash panel, center console and door panel assemblies.

Plant Manager (This was a pilot plant & the team consisted of rotating contract employees for various launches. There was no stability with business contracts, employees, etc. Preferred and requested full manufacturing facility within corporation, none available.)

Responsible for three plants producing and warehousing prototype parts, with non-union contract employees. Consistently exceeded budget goals each semester by over 10%.

Developed management team to define and install FES (TPS): receiving and inspection instructions, 5S, standardized work instructions, scrap reporting and production scheduling.

Installed new operating system (SAP).

Achieved TS-16949 and ISO-14001 certification.

AZ AUTOMOTIVE/SODECIA NORTH AMERICA, Sterling Heights, MI 2003-2010

A tier one supplier of metal stampings, robotic welding and assembly of automotive components.

Plant Manager (Company was bought out by Sodecia, who replaced entire management team within first year.)

Managed the Sterling Heights exclusively with a completely new management process to match the Sodecia model.

Improved OEE by 17% while reducing inventory levels by 54% ($1 million).

Used JIT, Visual Controls, and 5S to reduce safety incidents by 27%.

Multi-Plant Manager

Managed Roseville and Sterling Heights plants concurrently. (See Roseville review below.) Sterling Heights is a welding and assembly plant with over 150 employees.

Managed several successful program launches, meeting customer on time and quality requirements.

During economic downturn was able to reduce staff by 50% and still maintain plant efficiency, single digit parts per million (ppms) and zero premium freight.

Charnesky Resume’ pg. 2

Plant Manager

Promoted to hold full responsibility of the Roseville stamping and welding plant with over 300 employees.

Continued to break productivity and efficiency records while reducing customer ppm’s to below 5.

Job change over, scrap, obsolescence, customer complaints, and machinery down time reduced significantly below previous years budgeted numbers.

Cost reductions exceeded established goal and premium freight charges were not incurred in over three consecutive years.

Manufacturing Manager, Roseville

Lateral position change to expand knowledge and experience in preparation for plant manager position.

Installed a preventative maintenance program, SMED, and developed a manpower utilization program improving productivity by 15% year over year.

Consistently exceeded productivity goals by 11% including a record setting month while instilling 5S.

Material Manager, Roseville

Responsible for all material related functions and performed as Plant Manager when required.

Restructured the materials department personnel and all functional areas reporting to materials.

Using Lean principles, engineered pre-existing plant material flow and storage inadequacies as well as redesigned primary scheduling methods while reducing inventory by 30%.

Developed and implemented new production reporting and scheduling systems.

Implemented System 21/Future 3/Blackhawk operating systems.

PRIOR CAREER EXPERIENCE

NOBLE METAL PROCESSING, Warren, MI 2002

Noble Metal Processing is an industry leader in laser welding of automotive sheet metal blanks.

Material Director, Warren, Shelbyville, Brantford

AMERICAN AXLE AND MANUFACTURING, Detroit, MI 1998-2002

Major supplier of axle machining and assemblies-in-sequence to auto and truck manufacturers. Other products produced include forgings, stabilizer bars, piston rods, brake drums, drive shafts and net shape gears.

Corporate Material Manager, Detroit

Responsible for all corporate material reporting, supplier allocation, supplier delivery, bar coding, lot control/trace ability and system integration issues.

Material Manager, Detroit Forge

With annual sales of $240 million and 1,000 employees Detroit Forge manufactures pinions, axles, engine rods, and stabilizer bars for the automotive and truck market. Responsible for all material functions in 600,000 sq. ft. facility.

BOSCH BRAKING SYSTEMS, St Joseph, MI 1995-1998

Leading supplier of complete braking components to automotive and truck manufacturers. With 1,200 employees and annual sales of $350 million, the St. Joseph plant incorporates casting, precision machining and assembly into the 500,000 sq. ft. facility.

Material Manager

AEROQUIP CORPORATION, Chesterfield, MI 1995

Manufactured decorated interior plastics trim parts for 54 automotive customers and $24 million in sales.

Material Manager, Brentwood, Chesterfield, and Port Huron

LEAR CORPORATION 1990-1995

The Warren, MI plant services GM Pontiac East assembly plant and has annual sales of $75 million.

Material Manager, Warren, MI

The Detroit plant is a JIT automotive trim components supplier to 24 customers with over 156 outside suppliers. Produced products included full seat assemblies, headrests, rear seats, seat cushion foam, and metal stampings. Material Manager, Detroit, MI

Material Manager, Fenton, MI

The Fenton plant is a full service JIT sequencer seat supplier to GM with sales of $154 million annually.

Material Administrator, Fenton, MI

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