Manufacturing Operations Manager

Kacy McCarroll

**** ********* *****, **********, ***** 75077

972-***-**** *********@*******.***

LinkedIn URL: http://www.linkedin.com/in/kmccarroll

Manufacturing Operations Manager

A results-oriented business professional with a proven track record in strategic planning, improving efficiency of operations & managing a manufacturing facility. Able to identify areas of strength & weakness & implement company policies, standards, changes in operations that optimize productivity & the bottom line. Demonstrated ability to motivate staff, maximize productivity & control costs through the most effective uses of manpower & available resources.

Strategic Planning & Analysis Profit/Loss Improvements Team Building & Leadership

Customer Requirements Capital Improvement Projects Lean Manufacturing

Business Assessments & Audits Industrial Engineering Oversight EH&S Regulatory Compliance

A team player with skills in SAP, MAPICS, Microsoft Office/ Project/ Outlook, Visio, SharePoint, Solidworks, and AutoCAD.

Professional Experience

SAF Holland, Inc. (www.safholland.com) Wylie, Texas

150K Sq. Ft. Heavy Duty 5th Wheel Manufacturing Facility Trucking/Automotive Industry

Manufacturing Operations Manager Jul 2014 – Mar 2016

Managed a 3-Shift manufacturing operation, $90M in sales, 180 hourly /30 salary employees. Responsible for P & L, manufacturing labor & efficiency, cost reductions year over year & the facilities operational budget. Worked with our Corporate office in Michigan to streamline Engineering, IT & Customer Service solutions for the facility in order to meet “Customer Expectations” & “Customer Experience” requirements.

Consistently met or exceeded operational financial goals for the facility.

Implemented Lean Mfg. into the facility in order to create flow which helped the facility pass the new TS 16949 Audit the past 2 years.

Reduced the workforce from a 3-Shift Operation to a 2-Shift Operation due to the Trucking Industry economy in the last quarter of 2015.

Brand FX Body Company (www.brandfxbody.com) Fort Worth, Texas 300K Sq. Ft. Fabrication / Fiberglass / Install Assembly Facility Automotive Industry

Manufacturing Engineering Manager / Plant Management Jun 2012 – Feb 2014

Overseen manufacturing & labor efficiency by coaching 6 Plant Managers in different buildings on how to create flow using Lean Manufacturing. Worked with the Plant Managers overseeing Manufacturing Operations. Challenged with plant re-arrangements, and product moving from Iowa Facilities, logistics & ect. Reported to & advised CEO in all aspects of new business development, capital expenditures & operating budgets.

Transformed the Facilities from a Job Shop to a Manufacturing environment incorporating all the different plants locally & nationally.

Developed the Plant Managers to being a Leader, making Zone Leaders responsible for work cells.

Directed, planned and controlled the costs of the Maintenance Dept.

Moved large equipment Product Line into a new 60K sq. ft. building to make room for expanding sales in our Fabrication Facility of Aluminum, Steel, and Weld & Assembly.

Coached & developed our young Design Engineers on DFM & FMEA that are only a few years out of college.

Proactively negotiated terms on all contract work done within the organization including, materials, plant layout, facility construction & new equipment.

Steelcase, Inc. (www.steelcase.com) Grand Prairie, Texas 300K Sq. Ft. High-End Office Furniture Manufacturing Facility

Project Manager – Plant Management of Plant Closure May 2011 – Mar 2012

Managed the relocation of the entire 300K Sq. Ft. facility of 10 Value Streams to 2 Steelcase facilities in Reynosa and Tijuana, Mexico and to Finished Good Suppliers in the US. Organized and oversaw budgets, Value Stream re-locations, plant readiness and contract work produced in the facility.

Served as the liaison for Corporate in Grand Rapids, MI between the two Mexico facilities, and US finished goods suppliers for the Grand Prairie, TX Operations closure.

Considered a “key-player” during the plant closure and worked up until the last day of the plant being opened in Grand Prairie, TX and handing the keys over to the new owners.

Continuous Improvement Manager / Lean Facilitator Jan 2010 – May 2011

Managed the “Continuous Improvement” activities at the TX Operations Facility.

Facilitated Kaizen Team events throughout all the value streams and office settings to hourly and salaried personnel.

Appointed the Champion of each Kaizen and advanced associate’s leadership skills.

Worked with the staff to determine future Zone Leaders and Supervisors for the Texas Operations Facility.

Eliminated waste and reduced labor by 20% throughout the Value Streams.

Project Manager Jun 2009 – Jan 2010

Nominated by management to be Project Manager on a $3.8M customer “Special” order. Supervised Management Staff from all facets on the Project.

Oversaw and consulted on-site the installation of high-end office furniture in Chicago, IL for two months with the dealer, the installation crew and the customer.

Met “Customer Expectations” and “Customer Experience” objectives by hitting all the installation dates and completing the project on-time while maintaining quality craftsmanship.

Project Manager / Manufacturing Engineer Mar 2009 – Jun 2009

Managed $550K project combining production value streams and production equipment, freeing up 60K sq. ft. for a potential RDC warehouse.

Led Plant Engineering Kaizen Re-Layout pertaining to all the plant machinery equipment value streams from 18 to 10 value streams. 35% Labor Reduction, $674K Cost Savings, 8 month payback. Effectively communicated project progress, issues and financial status to executive management.

Met Steelcase objective by meeting customer expectations by being 100% water-based finished in our Clarity Finish Room.

Negotiated bids and justified expenditures working closely with the executive team at corporate office in Grand Rapids, MI.

Steelcase, Inc. (Continued)

Project Manager / Manufacturing Engineer Jun 2007 – Feb 2009

Project Manager overseeing a $2M project consolidating all manufacturing equipment out of 400 sq. ft. sister plant closure in Oakland, CA to the TX Operations Facility. Managed 9 Maintenance associates for 8 months.

Lead Manufacturing Engineer for a $30M value stream, 185K sq. ft. production area.

Managed 4 Contract Engineers on all Mfg. Engineering projects throughout the plant.

Led Water-Based/UV finishing conversion in Finish Room for Steelcase “green” products marketing strategy.

Designed an entire assembly line to assemble Tap Doors for a new conference top product line that included 7 fixtures and power torque drivers for the cell.

Project Lead re-arranging the TX Operations Facility making a 70% floor space reduction in order to fit the Oakland facility into the TX Operations using Lean Manufacturing Techniques.

Ashland, Div. of Newell Rubbermaid Lowell, Indiana

150K Sq. Ft. Injection Molding Facility

Plant Engineer / Project Manager Oct 2003 – Jun 2007

Managed a $900K budget for the manufacturing plant. Provided delegation, leadership and guidance to maintenance, tool room, and engineering personnel.

Implemented lean manufacturing techniques (Kaizen, 5S, Kanban, SMED, VSM) into the plant in 2005. Championed TPM events and machine cell Kaizen events.

Capitalized on $65K each year on Cost Savings for facilities and maintenance projects.

Project Engineer Mar 1999 – Oct 2003

Designed proprietary and custom injection molded and dies cast parts of window hardware components. Plastic Materials: Nylon 6. 30% GF Nylon 6, Polycarbonate, Acetal. Die-Cast Material: Zamak #3.

Project Manager & Tooling Coordinator pertaining to all domestic & import engineering projects in China.

Education

Bachelor of Science, Industrial Technology, Ball State University

Professional Affiliation

Society of Manufacturing Engineers

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