Experienced Plant Manager

Paul E. Kulniszewski

*** ****** *****, **** ******, New York 14224

Ph: 716-***-**** E-mail: ****.************@*****.***

Strengths and Qualifications

- Over 19 years of experience as a leader and manager in a dynamic manufacturing environment.

- Strong leader with good coaching and decision making skills who has brought together teams of hourly and salaried associates with an emphasis of developing individuals and blending them into an efficient and cohesive teams to meet the objectives of the company.

- Good multitasker with a strong work ethic, great time management, and excellent communication skills.

- Successfully developed and implemented inventory control and lean processes (modeled on Toyota Manufacturing System) in practices that resulted in increased throughput while at the same time drove inventory reduction, improved material flow, and increased efficiency of operations.

- Project Management experience with a launch of a 20 million dollar capital improvement project that successfully introduced a new process with new work practices into the plant. Worked closely with suppliers, maintenance, engineering, and the union to ensure the project was completed on time, on budget, and with union support and buy in

- Understands and is able to act upon the facilities profit centers, key quality and productivity drivers while driving accountability to all levels of a facility that generated over $200 million in sales annually.

- Responsibilities have included plant management, profit and loss management (P&L), production organization, human resources management, product development, scheduling, quality systems implementation, maintenance management, inventory management, risk management, budgeting, managing staffing, and planning of a facility at all levels, from floor supervisor to member of an executive staff

Professional Experience

Industrial Materials Recycling – Buffalo, New York (2012 –present)

Plant General Manager (2012 – present)

- Responsible for all aspects of a 1 million pound per month plastic recycling operation: Responsibilities are purchasing, sales, customer service, quality improvement, EHS, Finance, budget planning, cost management, production planning and attainment, performance management, inventory management, hiring and training, manpower planning, and maintenance planning.

- Built a Quality system from the ground up to comply with automotive clients strict supplier guidelines (ISO 14001) This system including written procedures, CAPA, daily production documentation, audits and quality inspections.

- Through data collection and cost analysis strategically developed a cost center for each production line and value stream at the facility. This allowed for the generation of effective goals at each line and helped achieve process improvements and cost reductions to maintain and increase profitability. Eliminated inefficient operations and reversed non-profitable value streams.

- Drive continuous improvement and encourage an attitude of accountability and ownership by providing consistent leadership and coaching though communicating plans, goals, and results by using regularly scheduled focused team meetings

- Moved company bottom line from one of loss to profitability by engaging the workforce, Leading problem solving workshops, setting goals, driving change, and following through by being accountable and holding all equally accountable.

- Planned and successfully moved all 5 operating lines, spare equipment, manpower, and inventory from one facility to another. This included site layout and design, hiring and supervising contractors to install necessary utilities, coordinating all equipment moves to ensure minimal downtime, cost, and customer interruption.

Aurubis Buffalo Inc – Buffalo, New York (2008-2012)

Casting Manager / Casting Assistant Manager (2010 – 2012)

- Responsible for all aspects of a three shift, 35 million pound per month metal casting operation: Responsibilities included quality attainment, safety, budget planning, cost management, production planning and attainment, inventory management, personnel management, and manpower planning.

- Managed Cast Shop maintenance and engineering staff, provided guidance and input for equipment PM planning, project planning, furnace rebuilds, station rebuilds, and material purchases.

- Worked closely with members of the Executive Staff to plan daily facility operations and to develop and implement plant policy changes and corporate directives. Worked with union to redevelop relations and change unproductive work practices

- Drove continuous improvement through using good manufacturing practices, team building and employee development by holding regular results-focused team meetings to improve quality, increase schedule attainment and reach our throughput objectives.

Production Coordinator / Metals Coordinator - Casting (2008 – 2010)

- Coordinated the delivery, quality, consumption, and flow of raw materials associated with a three shift casting operation.

- Accountable for the following; manpower scheduling, weight verification, proper tagging, and accurate data collection on 4 million pounds of raw material inventory. Lead Casting department Annual Physical Inventory.

- Created daily material usage plan and report card for tracking key performance indicators (KPI).

- Implemented a visual inventory system and housekeeping standards.

- Used FIFO philosophy to reduce raw material inventory by 1.7 million pounds.

- Generated $250,000 in savings annually by re-purposing scrap material and implemented inspection practices that prevented the receipt of 400,000 lbs of contaminated material per year.

American Axle & Manufacturing Tonawanda Forge - Tonawanda, New York (1996-2008)

Manufacturing Executive / Area Manager (2004 – 2008)

-Responsible for all aspects of a three shift, dynamic metal forging operation: Responsibilities included quality attainment, safety, production planning and attainment, mentoring supervisors, manpower planning, maintenance and equipment PM planning.

-Project Management experience with a launch of a 20 million dollar capital improvement project that successfully introduced a new process with new work practices into the plant. Worked closely with suppliers, maintenance, engineering, and the union to ensure the project was completed on time, on budget, and with union support and buy in.

-Worked closely with members of Executive Staff to plan facility operations and develop and implement plant policy changes and corporate directives.

-Implemented and maintained Lean tools to create value stream maps, standardized work, housekeeping, Heijunka boards, 5S systems, and internal pull systems that resulted in a 3 million pound reduction of material from the value stream and improved material flow

Manufacturing Production Coordinator / Supervisor Forge Operations (1996 –2004)

-Responsible for salaried supervisors associated with manufacturing while managing the production, material and quality across three shifts in my areas of responsibility

Education and Training

-Bryant and Stratton Business Institute – Business Administration program

-AAM Leadership in Manufacturing Skills- 200+ hours of Leadership, PFMEA, Lean Manufacturing, and Six Sigma training and workshops.

- AAM supervisor training skills - 80+ hours of Process, ISO, QS/TS, CAPA and QSB standards

- Microsoft Office, Excel, Word, and Power Point proficient

- OSHA 10 hour and lockout training

- City of Buffalo 1st and 2nd class Stationary Engineers license

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