Experienced Manufacturing Manager

Evgeni A. Bonchev

** ****** ****** *****: 312-***-****

Boca Raton, FL 33487 Email: **************@*****.***

Manufacturing Management Professional

Results driven and goal oriented manufacturing operations professional with 9 years of experience in food and dietary supplements manufacturing and packaging. Solid lean manufacturing principles background with a Green Belt Lean Six Sigma certification and extensive track record of cost savings and process improvements projects and initiatives. Demonstrated capability of building highly efficient production processes with optimal use of available capacities. Strong awareness of occupational hazards and effective and pro-active implementation of safety programs and strategies. Proven ability to build cohesive and motivated teams with focus on improved quality and controlled costs. Knowledge and ability to plan and manage annual and monthly budgets. Well accustomed to fast-paced work environment and capable of simultaneously and efficiently managing multiple tasks and priorities. Enjoys challenges and works hard to achieve sustainable results in all key performance indicator categories.

Areas Of Expertise

Budgeting and Cost Planning

Capital Expenditure Budgeting

Certified Lean Six Sigma Green Belt

Strategic Long and Short Term Goals and Strategies Setting

Change Management

HPO Implementation

Lean Manufacturing Principles

Root Cause Failure Analysis

Performance Reviews

Coaching, Mentoring and Succession Planning

Union Environment

External & Internal Audits

FDA and USDA Experience

SAP, Oracle and AS400 Experience

TPM Integrated Systems

Education & Professional Development

MBA, December 2012, Edgewood College, Madison, WI

Bachelors Degree, September 2004 Major: Hospitality Business Management, University of World Economics, Sofia, Bulgaria

Professional Experience

Business Unit Manager NBTY - Rexall Sundown

Boca Raton, FL (December, 2013 – Present)

Responsible for the building and management of annual budgets and operations of the warehouse, weigh rooms, blending and coating departments containing over 90 hourly associates and 4 salaried supervisors at an FDA regulated solid dose dietary supplements manufacturing facility.

In charge of the training, development and the quarterly and annual performance evaluations of four salaried supervisors and twelve hourly shift lead associates.

Facilitated safe work environment through daily safety observations program, immediate incident root cause analysis, on the job training of associates and supervisors and delivery of various safety programs.

Achieved a zero annual Total Incident Rate (TIR) with the implementation of a safety cutter tool eliminating the root cause of multiple laceration related incidents. Assisted in the development and implemented a peer to peer daily safety observation program.

Led the development of JHA (Job Hazard Analysis) documentation for each job within the business unit.

Implemented a LOTO program for the high injury hazard assets.

Facilitated compliance with plant Quality Systems programs, FDA regulations and audits by strictly observing and adhering to established GMP rules and regulations and industry standards.

Achieved a 98% First Pass Quality (FPQ), a 10% increase from previous year through reduction of documentation errors, NCRs and Deviations through timely training of associates and establishing a database trending errors and preventive measures of root causes.

Delivered KPI improvements in Overall Equipment Effectiveness (OEE), Cost Per Unit, Schedule adherence, People Productivity and defect reductions across multiple work centers through direct supervisor coaching, asset management and proactive execution of improvement projects and standardizing work across shifts.

Led the BU initiative of updating all SOP’s and creating Operating Instructions for each job and asset.

Introduced tools for OEE and downtime tracking and established baselines and databases for various department KPI’s.

Introduced labor model based on demonstrated capacity to optimize labor to volume fluctuations achieving a consistently cost per unit people productivity metrics.

Formulated the department annual strategy, goals and objectives to align with the plant and corporate OGSM (Objectives, Goals, Strategies, & Metrics).

Continuously focused on the implementation, execution, and improvement of Daily Management Systems (DMS), including safety observations programs, Centerline, Clean-Inspect-and-Lubricate, Total Productive Maintenance, Quality Defect Elimination as part of the High Performance Organization workframe.

Provided leadership and guidance building a High Performance Organization through problem solving, associate involvement and ownership, daily goal setting, GEMBA walks, team meetings, operational reviews, visual management boards and live time KPI reporting.

Delivered over $200K in cost reduction savings through production supplies optimization initiatives switching to reusable cleaning gear and auctioning supplies to the lowest bidding vendor.

Championed the Installation, Operational and Performance Qualifications (IQ,OQ,PQ) of four new department assets (three Acela coaters and one 175 cubic V-shaped blender).

Interim plant manager role Oct, 2015-Feb, 2016

Business Unit Lead Kraft Foods - Oscar Mayer

Madison, WI (June, 2011 – December, 2013)

Managed the 2nd shift operations for the entire plant facility containing over 450 hourly union employees and 15 salaried staff (maintenance, quality, sanitation and manufacturing supervisors).

Responsible for the training, development and leadership of junior Production, Maintenance, Quality and Distributions Supervisors and serving as a resource on the off shift.

Facilitated compliance and relations with USDA and plant Quality Assurance personnel by strictly enforcing plant GMP rules, SSOP/HACCP plans to ensure quality regulations are being met or exceeded by plant personnel.

Delivered KPI improvements in Overall Equipment Effectiveness (OEE), yield and defect reductions across multiple departments through direct supervisor coaching and coordination of departmental assets.

Supported the foremen’s and union work force activities in the implementation of Total Productive Maintenance (TPM) on the plant pilot line (Integrated Lean Six Sigma).

Identified performance improvement opportunities and gaps and delivered variable cost reductions through labor optimization projects in various departments.

Delivered cost savings through the implementation of numerous continuous improvement Lean Green Belt projects focusing on waste and defect reduction and OEE improvements.

Coordinated labor optimization projects resulting in over $180K of annual savings utilizing time studies data and lean six sigma Greenbelt tools.

Identified and executed a plant energy conservation project involving the reduction of light usage on non-working days with annual savings of nearly $80K.

Managed union contract questions and human resources related issues with the hourly workforce on the off shift.

Lead Operations Supervisor Kraft Foods - Oscar Mayer

Madison, WI (September, 2009 – June, 2011)

Ensured the focus of Quality, Cost, Delivery, Safety and Morale, as the foundation in all decisions.

Trained and lead a team of union employees and supervisors in problem solving, developed team maturity through coaching and counseling, and motivated the team toward achieving the department goals.

Developed and coached the 2nd shift and weekend shift supervisors in the department.

Coordinated and directed maintenance and continuous improvement (OPEX) functions in the department.

Coordinated production planning and labor scheduling, along with raw materials and supplies availability.

Identified OEE and lean improvement opportunities and coordinated project implementations with the maintenance, quality and continuous improvement (OPEX) groups.

Responsible for updating and creating new standard work rules, Detailed Process Sheets, Job Training Check Sheets and One Point Lesson documents and their implementation.

Lead the 3Sigma certification for one of the leading retail hot dog continuous processes (Kaizen, Standard work, Pre-control charts, OPL’s, facilitated the daily RCFA follow up meetings).

Delivered a Greenbelt scrap reduction project resulting in over $85K annual savings.

Increased the average weekly OEE on one of the leading slice lines by nearly 20% within 6 months from beginning of the assignment by focusing on standard work, training and minor capital projects.

Business Unit Manager role on interim basis from January-March 2011.

Launched multiple successful weekend shifts with new hire team members. Improved OEE by 8-15% in all supervised process and significantly reduced waste and defects.

Production Supervisor Kraft Foods - Oscar Mayer

Madison, WI (May, 2007 – September, 2009)

Supervised various plant operations (Lunchables Raw and RTE, Square Prep, Sanitation, Round and Square Cold Cuts Slice, Value Shaved, Retail and Food Service Hot Dogs) with teams of 15 to 60 hourly union employees.

Worked closely with equipment vendors, corporate engineering, mechanical and sanitation groups during the commercialization of a new multimillion retail hot dog continuous process.

Successfully ramped up three new weekend shifts in hot dogs and round cold cuts departments.

Responsible for the management of daily operations in various production processes. Lead and supported the lean and 5S continuous improvement efforts in operations, quality and safety.

Delivered sustainable OEE results in the coordination of maintenance work requests in SAP for all shifts for the leading hot dog line at the Madison plant.

Worked closely with equipment vendors, corporate engineering, mechanical and sanitation groups during the commercialization of a multimillion state of the art continuous production line. Met all established Yield and OEE targets during the ramp up period.

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