MICHAEL G. GAINES
Kansas City, MO 64114
*********@*****.*** linkedin.com/in/mikeggaines/ 734-***-****
Director, Manufacturing Engineering
Continuously improving current operations while building the future
Extensive hands on experience in product/process engineering and development, equipment, tooling, gauging and facilities design, project facilitization and preventative/predictive maintenance. Excellent analysis, innovation and problem solving skills including multiple process and product patents. Adept, with over 30 years acquiring supporting multi-disciplinary skillsets in production, scheduling, manufacturing cost accounting, capital appropriation systems, quality systems, logistics, supply chain and major project management. Significant Tier 1 automotive and consumer goods experience excelling in managing in multi-tasking environments with challenging cost, quality system and timing constraints. Proven ability to lead the accomplishment of strategic initiatives that support the vision of the organization and drive implementation of new and enhanced technology and process improvements.
AREAS OF EXPERTISE
Design for Manufacturing/Assembly DFM/A)
OEE (Overall Equipment Effectiveness)
TPM (Total Productive Maintenance)
MRP / ERP Systems
APQP New Product Launch and ISO Quality systems
Lean Manufacturing and Six Sigma tools
JIT (Just In Time) Delivery and Sequenced Delivery
Management of multiple projects and project locations
Capital / Expense Appropriation Budgeting / Preparation
Capital Equipment and Facilities Specification, Quoting and Purchasing
Cost reduction processes and practice
Acquisition Due Diligence - Product, Process, Manufacture
Strategic and tactical business planning
Health / Safety / Environmental Compliance
HEARTLAND MANUFACTURING GROUP, Peculiar, MO. 2014 – Present $8M manufacturer of custom designed and built steel buildings
Operations Manager reporting to the President
Leadership of scheduling, engineering and detailing, production and MRO purchasing, manufacturing, quality, inventory, shipping and receiving, building and grounds, and Environmental, Health and Safety conformance.
Reduced absenteeism and employee turnover 25% through active interface with hourly employees and responsiveness to concerns and suggestions.
Successfully addressed previously existing Federal OSHA remediation requirements and two MO OSHA partnership inspection remediation’s.
Implemented Process Capability Analysis and Design For Manufacturability initiatives to enhance building ease of assembly and identify areas for continuous improvement.
Year over year increase in building shipments of 6%.
L-Z-BOY RESIDENTIAL, Monroe, MI 2005 – 2013
$1B+ manufacturer of built to order custom residential furniture.
Director, Manufacturing Engineering reporting to the VP of Continuous Improvement & Lean Manufacturing. Provided centralized, multi-facility, manufacturing and industrial engineering direction and support for 7 Plants,
6 Supply Centers and 5 Distribution Centers located throughout the USA and Mexico. Managed two direct engineers and one engineering manager with extended support provided to 25 plant facility, manufacturing engineering and component supply center managers with direct support to distribution center managers.
Provided review, oversight, technical and major project support for capital projects averaging over $10M/year assuring conformance with planned financial, capacity, quality, safety, and environmental objectives.
Key leader and Manager in a 3year, $34.3 Million cost, transformation of a multi-facility, old line manufacturing operation into a Lean Manufacturing organization with a strong Continuous Improvement culture using Six Sigma tools and currently saving over $27 Million/year.
Directed the design and build of 31 custom cellular packaging machines installed across 8 facilities at a cost of $952K producing an annualized savings of $973K/year.
Managed 4 plant consolidation projects integrating capacity into other existing facilities with no lost production, all key assets redeployed and surplus assets dispositioned.
Provided simultaneous engineering and APQP implementation support for two major new product mechanism projects at a cost of $1.313 million enhancing major product lines leading to increased sales and profitability.
Led the design and complete facilitization of a $2M, 145K sq. ft. Distribution Center saving $943K/year.
Core team leader in the design and facilitization of a Cut and Sew Facility in Mexico including consolidation of equipment from 7 facilities. Managed manufacturing costing, design and build and achieved full Lean flow and process at a 700K sq. ft. leased facility with a cost of $13.6M, saving $25M+ a year.
ALMA PRODUCTS COMPANY, Alma, MI 2003 – 2005
$60 Million/year manufacturer/remanufacturer of automotive air conditioning compressors and torque converters.
Director, Quality and Continuous Improvement reporting to the General Manager, Alma Products.
Led quality management as well as cross-functional continuous improvement at 2 plants in a recovery role. Managed one supervisor with 4 technicians and 5 engineers as well as vendor development in China.
Achieved turnaround of poorly functioning operation and engineering areas, improving productivity and quality rates year over year by 17% while reducing critical delivery times.
Maintained QS-9000 certification through 3 surveillance audits and attained ISO-9001 certification.
Supported a companywide cost savings program implementation yielding $4M/year in cost reductions.
Championed cross functional improvement initiatives and introduced Lean Manufacturing concepts reducing WIP inventory and throughput time, as well as excess finished goods inventory15%+.
Managed the introduction of a new product line incorporating substantial international content and provided on-site support to multiple vendors in China.
RELIANT ENERGY POWER SYSTEMS, Houston, TX 2001 – 2002
Independent start-up within a $45B utility company. (Company closed in 2002 due to funding reduction)
Director, Manufacturing and Engineering reporting to the Vice President of Reliant Energy Power Systems.
Spearheaded product and process engineering, manufacturing and quality disciplines focused on development and consumer introduction of a residential / commercial, 0 - 5 KW, PEM fuel cell product line.
Design concept through build of physical proof of concept of a 5KW alpha test platform system in 1 year.
Managed project planning, staffing and design for manufacture of a beta product utilizing the APQP process.
Oversaw supplier and contract management as well as industry and potential customer contacts.
Two patents were issued for developed technology.
SPARTENBURG STAINLESS PRODUCTS, INC., Spartanburg, SC
$30M specialty stainless steel products.
VP Technical Services reporting to the President of SPARTENBURG STAINLESS PRODUCTS, INC.
MIDWAY PRODUCTS GROUP INC., Monroe, MI
$300M Tier I supplier of stampings and assemblies
Director, Product Engineering and Development reporting to the Vice President of Engineering
BIL-JAX INC., Archbold, OH
A $50M manufacturer of construction scaffolding and aerial lifts.
Vice President of Manufacturing reporting to the President of BIL JAX INC.
TENNECO AUTOMOTIVE, Monroe, MI
A $3.2B manufacturer of suspension and exhaust systems.
Executive Director Product & Process Integration / Plant Manager / Director Manufacturing Systems
Bachelor of Mechanical Engineering, Mechanical Electrical Option
General Motors Institute (now Kettering University), Flint, MI
4564138-Gas pressurized shock absorber assembly * 7001687-Unitized MEA Assemblies and methods for making same 4712353-Gas pressurized shock absorber assembly * 4866966-Method and apparatus for producing bypass grooves 5474367-Actuation member for a Proportioning valve for load leveling applications * 7005209-Fuel cell stack assembly 7585018-Wall proximity reclining chair with in-line linkage mechanism