Charles Balko

PO Box *** 215-***-****

Skaneateles, NY 131522 actoc6@r.postjobfree.com

Career Overview

Self-directed manufacturing professional, offering diverse leadership experience within HVAC, housing, and auto manufacturing industries. Experienced achievements within start-ups, equipment and facilities upgrades and turn around management. Developed and executed manufacturing strategies and optimized overall operations that achieved millions of dollars in cost reductions and productivity gains while operating in a demanding customer driven environment.

Areas of Knowledge & Experience

Lean Manufacturing Operations Management Labor Relations

Maintenance Management Facilities Engineering Process Engineering

Quality Systems Environmental Health & Safety Business Financials P&L

Manufacturing Engineering International Product Transfers Project Planning

ISO 9000 Six Sigma Visual Factory

Professional Experience & Selected Accomplishments

Daikin Applied, Auburn, NY. 2010 - Present

Production – CIP Manager: HVAC Manufacture: Hired as Senior Manufacturing Engineer, quickly promoted to lead the Cost Improvement Project team for the plant. In addition, oversaw the logistics, training and line layouts for the transfer of equipment and personnel to SLP, Mexico prior to local plant shut down.

Exceeded the Plan and Stretch Objectives each year with an average annual savings of $5 million.

Led VA/VE event, which resulted in $36 per unit savings on Vertical Stack Product.

Developed capacity plans and strategies for dual production during international product transfers allowing for the continued build in Auburn while moving machines and equipment to SLP, Mexico.

Led international product line transfers including plant layout, standard work, training, CER and

staffing requirements.

Reworked or created work instructions (OMS) for all departments used for training and international product transfers.

Oversaw 5 Manufacturing Engineers as direct reports; personally trained them to develop OMS work instructions from Video’s of production and SolidWorks solid models.

Led team designing and building water and refrigerant circuit fixtures for all product lines needed for international product transfer.

Led team responsible for split production of UV product, built in two countries, including Plant layouts, chassis and end unit configurations, stocking levels, manning levels, training documentation and CER.

Increased efficiency on main line by 22% by process improvements, fixtures and standard work.

Set min-max levels for all purchased and manufactured parts for UV product after split production.

Took on added duties of Maintenance Manager for six months until plant could find replacement.

Charles Balko Page 2

Toll Integrated Systems, Horsham, PA. 2003 - 2009

Plant Manager: Complete P&L while directing 4 Production departments: Logistics, Maintenance, Shipping/Receiving and Customer service comprised of 265 hourly and 35 salaried personnel, for the nation’s premier home builder Toll Brothers.

Implemented Lean Manufacturing, Visual Factory, JIT delivery, and Standard work and cross-trained the workforce. Results: 275% improved plant efficiencies and an increase of $52 million in sales.

Increased Inventory turns by 20% and lowered on hand inventory by $4.5 million dollars in an 11-month period by better utilization of JDE MRP system.

Reduced Labor to Sales ratio from 16% to 8.5% while increasing salaries by $5 an hour by applying effective supervisory counseling to set goals and objectives for the workforce.

Introduced Lean Manufacturing, Visual Factory and 5S to entire plant.

Lowered lead-time for product delivery from 14 weeks to 6 weeks.

Ford Motor Co, Edison, NJ 1990 - 2002

Manufacturing Engineering Manager: Auto assembly plant producing Ranger and Mazda Pickup trucks.

Responsible for two shifts of 115 Hourly and 15 Salaried personal. Held the following positions prior to Engineering manager: Maintenance Supervisor, Process Engineer, Automation Engineer, Process Engineering Supervisor, Production Supervisor, Production Manager, and Area Manager.

$30 Million dollars of approved projects written and installed on time without issues.

8 Model change launches, 6-facility change launches on time and under budget.

First Six Sigma project became company’s Best Practice.

Led QS9000, ISO9000 and ISO14001 roll out along with Safety, Quality, Delivery, Cost, Morale and Environment (SQDCME) initiative.

Second Six Sigma project lowered Warranty CPU by $5 per unit and improved warranty position from 23rd to 4th place out of 24 Ford assembly plants.

Promoted 8 times in 12 years.

Special Recognition: Earned the Customer Driven Quality Award & Most Improved Paint Shop Award

Education & Professional Development

BFA, Syracuse University, Syracuse NY

Ford Training:

Toyota Production System

Theory of Constraints TOC

Lean Manufacturing

Six Sigma Training

Fanuc Robotics

A&B PLC 2, 3 & 5

Master Electrician License New Jersey EIO8899

HACCP Manager, Health Hazard Analysis Critical Control Point, NSF International

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