Manager Plant
Resume:
Duncan Gray
******.********@*****.***
EXPERIENCE SUMMARY
Experienced Plant Manager with over 25 years of senior management responsibilities who is focused on continual improvement. An operational leader who enjoys mentoring and teaching others, using an active approach that solves current issues while developing the team. Demonstrated in-depth knowledge of: manufacturing, lean, quality principals, systems, and tools. A problem solver who is detail oriented and results focused.
PROFESSIONAL EXPERIENCE
AVON Automotive 2015
Tier 1&2 Supplier of extruded rubber hoses
Plant Manager
Developed system for forecasting manpower and overtime requirements in addition to capacity planning. Reduced unscheduled OT by over 50 %
Lead team to reduce parts on containment by 35% by establishing review of corrective actions, validation of effectiveness, and daily tracking of sort results.
Realigned Staff Meetings, Production Meetings, and Hot Parts meetings to improve effectiveness. Changes improved communication, accountability, and reduce Premium Freight by over 50%.
Established systems to track and improve the process of prototypes and sample production in working with the corporate engineering team.
Developed Inventory Action Plan to reduce variability during physical inventory, including review of B.O.M. issues and placing controls on scanning errors.
MINTH- PTI 2013-2015
Tier 1 & 2 Supplier of Plastic Trim components (500+ employees)
General Manager –Multi Facility -$110M Sales, (84M Mfg – 26M Pass through)
Full P&L Responsibility driving performance from $9.2M loss to profitability via consolidation of facilities ($500K), reduction in Premium Freight ($1M), 3rd Party Sorting ($1M), scrap (2.5M), and other variances.
Realigned product strategies based on product line margin increasing profitability.
Arraigned shop floor layout to minimize material handling equipment and personnel via changes in machine locations and drop zones.
Implemented visual controls from Senior Management Dashboard to Shop Floor Production boards to turn MINTH Tawas into a data driven organization. .
Maximized employee output via job reorganization and material handling robotic systems to match TAKT time of customer.
Cooper Standard - Gaylord 2008-2013
Tier 1 Automotive Supplier of rubber and plastic extruded and molded parts
Quality Manager / Engineering Manager / Program Manager
Responsible for receiving, investigating, and responding to customer concerns utilizing problem solving tools and robust corrective actions.
Supervision of quality, engineering and maintenance personnel including tracking of completed task on preventative and predictive maintenance, and staffing requirements.
Responsible for Product Cycle including quoting, sourcing of tooling, tracking of A.P.Q.P. elements, thru PPAP. Development and review of Process Flow, PFMEA development and correlation with DFMEA, Gage development and buy-off.
Lean activities including, qualification, documentation, implementation, and tracking of spending.
Plant and cell layout, material flow optimization, ergonomic and productivity improvements
Benteler Automotive – Galesburg 2005-2008
Tier 1 Automotive Supplier of Welded Assemblies
Quality Manager
Completed FORD MSA for Q1 recovery including corrective action closure.
Represented company in the FORD Way-Forward program including data collection, administration, and reporting
Implemented system for review and closure of corrective actions. Eliminate backload of 170 open concerns and reduce time to close by 80 %
Lear Corporation –Roscommon 2004-2005
Tier 1 Automotive Supplier of Metal Stampings, Welding, and Assemblies
Quality Manager
Converted QS-9000 system to TS16949 receiving registration.
Customer concerns reduced from 13 per month to 2, open concerns from 180 to 5.
Developed Layered Audit system in compliance with Chrysler and Lear requirements.
Android Industries Inc. 2002-2004
Containment Organization- Quality Solutions Manager
Full P&L Responsibilities for the QSG Michigan Division
Radar Industries Inc / Anchor Bay Industries 1998-2002
Tier 1 Automotive supplier of stampings and welded assemblies.
Radar -Quality Manager / ISO14001 Representative
Responsible for Quality Department of stamping/ welding/ assembly plant.
Responsible for Environmental Management System development, implementation and maintenance
Anchor Bay -General Manager (Plant Manager)
Note: Position eliminated at Anchor Bay Industries as result of plant consolidation to Radar.
Full P&L Responsibilities for Facility.
Increased productivity 30% via ergonomic improvements, lean activities, and work force stabilization (Annualized savings in excess of $130,000)
Coordinated review and improvements to robotic welding cells and fixtures to improve process capability and reduce wire usage.
Reduced personnel requirements via process flow and scheduling enhancements (Annualized savings $225,000)
Provided cost analysis review and summary during consolidation review and process.
Howell Industries 1993-1997
Tier 1 Automotive Supplier of stampings, welded and assembled parts
Corporate Director of Quality Assurance
Developed, implemented, and maintained a QS-9000 Quality System for a multi-facility Organization.
Managed the Advance Quality Planning efforts for the largest program in company history, including the establishment for Significant Characteristics and gauging strategy.
Education:
Davenport University, Flint, MI
Bachelor in Business Administration
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