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Manager Six Sigma

Simpsonville, SC
February 29, 2016

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Nathaniel Thomas Jr. 864-***-****

Simpsonville, SC 29681

Manufacturing Manager

Military Veteran ( US Army)

Six Sigma Green Belt certified Manufacturing Manager. Effectively manged all aspects of manufacturing- Safety, & health, environmental, reliability, quality, productivity, cost yield, compliance and capital/maintenance investment. Experienced in Implementing, developing and sustaining High Performance Work teams. Direct and indirect responsibilities for salary and hourly operation employees. Safety excellence through promoting employee involvement, ownership, and accountability to proactively identify and mitigate critical hazards. Seven years production leadership managing multiple departments in a fast paced packaging facility.

Professional Experience

Sealed Air/Cryovac Packaging, Simpsonville, SC 2000 - 2015

Value Stream Project Leader 2014 - 2015

Lead the installation of new equipment and developing process flow of materials. Coordinated the development of a training manual for all employees assigned to equipment.

Completed machine installations, utilizing detailed Action Register to ensure machines were moved and employees trained to meet target goal of 7 days.

Achieved goal of removing 2 pouch machines from plant in North Carolina and Installing machines in SC plant within 7 days turnaround time.

Coordinated 5S Kaizen to organize pouch machine production work cell providing employee “ownership” which improved maintenance, morale, productivity, safety and transparency.

Eliminated wood pallets from RS Slitting and replaced with a plastic pallet which reduced pallet types from seven to two and minimized near-miss accidents from 53 to 0 incidents and also generated yearly cost savings of $450,000 per year.

Film/Roll Stock Converting Department Manager: 2009 - 2014

Champion for productivity/ 5S Lean initiatives and cost reduction projects within the Film/Roll Stock Converting operations. Department leader for 175 hourly employees and 4 salaried employees producing $150 million worth of sales in a High Performance Work Team Environment (HPWT). Experience in labor management, Quality, Lean, and Continuous improvement in a manufacturing environment.

Achieved over 900 days without medical accident in Film Converting by Facilitating employee driven safe card process to prevent first aid and medical accidents.

Saved $150K by implementing HPWT in both departments which consisted of 16 teams operating and utilizing six resource roles to provide direction and coordination for teams. Achieved 21% increase in rate improvement by completing implementation of TPL (Team Performance Leader) role in RS Slitting.

Nathaniel Thomas Jr. 864-***-**** Page 2

Achieved over 545 days without medical accident in RS Slitting by using 5-Why and Tap-root problem solving to determine root causes and implemented procedures to audit progress and prevent further accidents.

Streamlined and improved process flow of materials through RS Slitting by reducing changeover times and developing effective back-ups plans to compensate for unscheduled maintenance downtime on slitting equipment along with meeting customer required ship dates. ( Contributed to achieving 21% rate improvement)

Awarded Gold, and Bronze Keys to Success awards for World Class Manufacturing Projects completed in RS and Film Converting out of 290 Lean Six Sigma projects submitted.

Developed strategy and business planning for department: manpower requirements, capital requirements, overtime requirements and capacity planning.

Film Plant Department Manager: 2006 - 2009

Change agent working with a group to achieve best-in-class performance in relation to Safety, Quality, Cost, and all aspects of production, for the Extrusion and Converting operations. Provided coaching for 4 Supervisors, 4 Shift coordinators and 140 team members working on 3 and 4 shift operations.

Sponsored the first Kaizen at Simpsonville location making critical improvements in converting process which resulted in 33% rate increase by using 5S, & DMAIC principles to level load the work flow and eliminate waste in the work cell.

Sustained strong ISO program to maintain ISO certification and developed process to perform monthly audits of the departments ISO documentation along with creating action register to track and correct non-compliant items.

Generated cost savings of $500K/year in scrap reduction by using Pareto analysis of defects and leading a production team to improve new product yields by over 10%.

Developed strategy and business planning for department: manpower requirements, capital requirements, overtime requirements and capacity planning.

Film Extrusion Department Manager 2000 - 2006

Managed capital, materials and process to produce semi-finished film conforming to Sealed Air’s quality and cost standards along with facilitating budgeting and labor utilization process.

Saved $200,000 by leading production team size reduction of 20% without impact to service, quality or productivity.

Achieved 7.4% yield improvement in extrusion which included yield improvement, product rationalization, resin replacement strategies, and set-up improvement.

Reduced cost per kilogram from $1.21 to $0.94 (22% reduction) using root cause failure analysis and set-up changeover process.

Education and Professional Development

Bachelor of Science Degree, Biology - South Carolina State University, Orangeburg SC

Executive Leadership Training

DuPont Safety Training

High Performance Work Team training

Advanced HACCP Training

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