Plant Manager

Judson Waters

**** ********* ****** ***********, ** 47401 PH (H) 812-***-**** (C) 812-***-****

Email: ************@*******.***

Objective

Senior Level position in Manufacturing

Summary:

BS Industrial Tech. with 27 years of operations & production management experience. Supervised up to 400 production/ packaging personnel over 4 shift operation.

16 years experience in Coating/Laminating and Converting PS Label Stock. 9 years of experience in plastic manufacturing, 3 years in flexible packaging industry.

Extensive experience with various production operations including slitting, color printing, lamination, blown film and converting for bags, etc.

Trained as 6 Sigma Black Belt and Lean Facilitator. Coached multiple Green Belts/Projects.

Experience in new site requalification, commissioning, start up, new product transfer, project implementation etc.

Handled all aspects of operations management, including resource planning/scheduling, department budgeting, cross-functional training, performance reviews, safety compliance, production goal setting, finance, etc.

Responsible for plant P/L and financial reporting.

Experience

Present Independent Consultant Bloomington, IN

Provide Energy Management strategies including electrical and natural gas pricing

contracts, lighting redesign, and water conservation.

2010 – 2013 Technicote Miamisburg, OH

Director of Operations

Manufacturer of pressure sensitive label stock and release liners primarily for product identification applications

Reporting directly to the President; responsible for all Manufacturing, Purchasing, Scheduling

and Logistical functions for the company. Direct reports included the Director of Purchasing

and four Plant Managers.

Began my assignment as Plant Manager at the largest facility located in Terre Haute, IN with intent to

take over for retiring Director of Operations. Mentored the individual targeted to

replace me when I transitioned, and completed 2011 with company meeting all business objectives.

Lead 2012 budgeting process and completed capital and improvement project plan for all

plants.

Devastating fire destroyed our primary custom products facility in Cuyahoga Falls, OH on

December 13, 2011. Revised our staffing and manufacturing plans to move products and

personnel to our other three facilities. Lead all activities in identifying best path forward as

to rebuilding or moving to a new location. Worked with local government agencies and

received tax abatements in excess of $1MM which convinced owners to rebuild on existing

site. Lead the selection process of General Contractor and building design and monitored the

complete construction project. Building was complete in four months and replacement of

coating and slitting capacity was complete in six months. Moved all personnel and products

back to Cuyahoga Falls in less than one year after the fire.

2007 – 2009 Main Tape Cranbury, NJ

Director of Operations

$48,000,000 business focused on the manufacture and distribution of pressure sensitive

protective films for the building products and metal protection markets.

Reporting directly to the President; responsible for all Manufacturing, Engineering, Quality, Customer Service, and Supply Chain functions

Turnaround situation requiring a focused approach and development of a 5 year strategic plan.

Objective was to double the business within 5 years through a combination of acquisition and growth.

Restructured the Management group to support the change process. Developed metrics,

performance plans, and other feedback mechanisms to ensure that direction was maintained

toward established goals.

2007 Covalence Plastics Battleboro, NC

Production Manager

$112,000,000 business focused on the manufacture of blown film sheeting and bag products. One of the 3 largest blown film plants in the US utilizing 45 monolayer film lines and a variety of folders, separators, winders, and bag machines for inline converting.

Responsible for safety and management of 400 production personnel in a 24/7 operation producing

400,000 lbs. of finished product daily.

Achieved 1 year with no Lost Time Injuries. Reduced recordable injuries from 26 in 2006 to 6 for 2007

through routine audits and communication.

Restructured the Quality Department which reassigned 36 quality inspectors into four manufacturing teams. This improved communication and reduced problem solving time.

Helped design new hiring, internal training, and performance feedback process. Objective was to

reduce turnover and dependency on temporary personnel.

Reduced Scrap by 15% in first 4 months and achieved first profitable monthly performance in 2007

2003-2006 National Salvage & Service Corp. Bloomington, IN

Operations Director/Contract Manager

Responsible for Managing Corporate Demolition and Environmental Remediation contracts.

Manage field superintendents and coordinate project activities with owners and government entities. Responsible for developing project time lines, support plans development and submittal, permits, budgets, and facilitating changes and disputes.

1999-2002 Pliant Corp. Odon, IN

Operations Manager-Indiana Operations Odon Facility

Responsibility for $22MM business focused on the manufacture and distribution of Custom and Barrier Blown film primarily for the Cookie, Cracker, and Cereal Markets. Equipment utilized were four 3 layer and one 5 layer Gloucester lines.

Achieved 2 years with 0 Recordable Injuries and 6 years no Lost Time Injuries through relentless focus on unsafe acts and conditions. 100% plant involvement in 2 permanent safety teams.

Customer Credits reduced to .01% of sales. Results driven through structured Corrective and Preventative Action process involving both operations and customers.

Internal Net Scrap reduced to 1.5% by ensuring defined customer specifications within our process capabilities. Maximizing reclaim of trim and internal rejects.

98% On Time shipment achieved by daily review of any Safety, Quality, or Process issues impacting service.

1997-1999 Superior Label Systems Inc. Mason, OH

Quality Manager Prime and Line Label Divisions (98-99)

Responsible for the quality system for both Flexographic Printing divisions which included Art and Plate Making. Process capabilities included both wide and narrow web printing up to 8 color. Media included both pressure sensitive paper and films.

Expanded the used of Corrective and Preventative action through a team approach which included production, accounting, sales, and the customer. The focus was on ensuring well defined product specifications which were also within our process capabilities.

Operations Manager Creative Media Products Division (97-98)

Responsible for manufacture and distribution of Thermal Transfer and Direct Thermal labels to the Print on Demand market. $6MM division of Superior Label Systems with Estimating, Purchasing, Customer Service, Manufacturing, and Shipping Responsibilities.

Introduced elements of ISO 9002 standard to address Customer Credits. This resulted in established Corrective and Preventative Action Processes that resulted in returns being reduced from 3% of sales to .4%.

Introduced Capacity Planning process that allowed Customer Service to accurately forecast daily capacity and balance customer demand. This resulted in On Time Shipment performance improvement form 49% in 1997 to 94.5% in 1998. In addition, standard lead times for repeat business were reduced from 7 days to 3 days.

1985-1997 Avery Dennison, Fasson Roll Division Ft. Wayne, IN

Manager of Training & Organizational Development (1991-1997)

Managed outside consultants and coordinated activities focused on organizational systems redesign and deliver of focused training for this manufacturer of Pressure Sensitive Paper.

Redesigned Safety, Communications, and Performance Management systems contributing to 77% reduction in Recordable Injury Incident Rate, 22% reduction in Losses, and a 50% improvement in Quality Measurements.

Managed HR and Safety function during last two years of this assignment. Responsible for annual wage and benefit surveys, performance management systems, and hiring/, firing decisions.

Plant Engineering Manager (1989-1991)

Management of 13 member Maintenance and Engineering Department responsible for up keep of building and grounds, plant security, local and corporate capital, and all Mechanical and Electrical Engineering activities.

Responsible for development and management of $12MM expense budget.

Manager of Quality and Performance Improvement (1988-1989)

Worked at the local and division level to design and implement a Continuous Improvement Process based upon solid Quality Planning and Project Management.

Production Unit Manger (1985-1988)

Responsible for the direct management of all manufacturing and distribution activities including Receiving, Shipping, Compounding, Coating, and Finishing. Part of the original start up team for the Ft. Wayne manufacturing facility.

1981-1985 Chesebrough Ponds Inc. Jefferson City, MO

Production Supervisor/Plastics Molding Division

Education

B.S. Southern Illinois University, Major: Industrial Technology. Maintained 3.5 GPA while on active military duty

Licensed Instructor for Zinger Miller Frontline Leadership

Certified facilitator in Kepner Trego Problem Solving and Decision Making Processes

Certified facilitator of Socio Tech Redesign Processes

Trained as 6 Sigma Black Belt

40 hour HAZWOPR trained

Completed 40 hour OSHA for General Industry Safety & Health and Construction Safety & Health

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