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Manager Plant

Aiken, South Carolina, United States
October 12, 2016

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Brian A. Lane 567-***-****


Manufacturing operations leader with extensive training and experience implementing lean manufacturing principals. Core competencies include Hoshin Planning, SIOP, Toyota Production System, Lean Transformation, Project Management and TS/ISO Quality Systems. Technical competency in stamping, tool management, welding (resistance, MIG, TIG), and robotic applications. Excellent problem solving skills. Strong financial and business acumen. PROFESSIONAL EXPERIENCE

THE CARLSTAR GROUP, Aiken, SC 2014 – 2016

Director of Operations (2014 – 2016)

Managed a 2-plant operation that produce tire and wheel assemblies for agriculture, lawn and garden and aftermarket automotive and ATV customers. Annual sales exceed $400M with over 500 employees. Processes include stamping

(50T-600T), roll form, robotic welding, painting. Established strategic direction and facilitated improvement in plant KPI’s through pareto analysis, root cause corrective action and continuous improvement activities.

Led EBITDA improvement from 10% to 25%.

o Rationalized and substituted negative margin products. o Eliminated non-value added activities in direct and indirect labor positions utilizing process mapping and kaizen activities.

o Implemented tool management process reducing annual tooling repair cost by $200,000.

Managed installation of servo feeders on 3 blanking presses resulting in 60% scrap reduction.

Eliminated past due orders in excess of $2M utilizing MRP system and driving work order completion metrics.

Achieved safety improvement from 12 recordable injuries in 2015 to 4 in 2016. Plant Manager (2014)

Managed plant and distribution operation that produced steel wheels for OEM’s in agriculture, lawn and garden markets. Annual sales exceed $130M with 270 employees. Major customers include John Deere and Husqvarna.

Drove EBITDA improvement from 8% to 15%.

o Labor cost reduced 16% through work content analysis and waste elimination activities. o Reduced discretionary spend by $500K by eliminating non-value added processing and implementing die detail coating and roll on press lube application. o Improved equipment uptime from 55% to 93% by organizing refurbishment of 5, 600T transfer presses and implementing maintenance performance metrics driving improvement activities.

Managed capital projects exceeding $5M which included paint system, central die lube application, new and refurbished stamping dies and 7 automated weld cells.

Oversaw insourcing of 50 stamping dies when key supplier went out of business. Selected die shops for refurbishment, negotiated pricing, managed supplier timelines and attained PPAP approval.

On Time Delivery improved from 74% to 98% by implementing metrics, visual controls and Kanban scheduling.

Reduced WIP inventory $2.2M and freed 70,000 sq./ft. of manufacturing floor space by converting batch process to flow utilizing lean layout strategies.

MIDWAY PRODUCTS GROUP, Hudson, IN 2012 – 2014

Plant Manager

Managed plant operation of a Tier 1 automotive supplier producing structural components for OEM customers. Annual sales exceed $54M with 300 employees. Primary customers include Ford, General Motors, Chrysler, and Toyota. Processes consist of 40% stamping (100T to 2000T), 20% roll form and 40% robotic welded assembly.

Launched over 30 new programs utilizing APQP guidelines, project management and statistical process validation.

Achieved 18% improvement in customer quality performance over previous 12 months achieving single digit PPM’s for 8 consecutive months.

Improved OEE (Overall Equipment Effectiveness) performance improvement by 12% over previous year. Brian Lane 567-***-**** Page 2 of 2

GKN, Various Locations 2007 – 2012

Plant Manager – Emporium, PA (2010 – 2012)

Managed 170-employee plant operation that produced powdered metal components to OEM automotive, Tier 1 automotive and industrial customers. Annual sales exceed $40M. Primary customers included General Motors and Briggs & Stratton. Process included powdered metal mixing, form press, sintering, heat-treating, and CNC machining.

Reduced quality defects 70% achieving external PPM levels below 300.

Improved On Time Delivery from 45% to 95%.

Achieved 15% year over year OEE improvement.

Presented with GKN Presidents Award for development and implementation of an autonomous maintenance program.

General Manager – Jackson Center, OH (2009 – 2010) Managed stand-alone business that manufactures non-powered axles, hubs and spindles to various trailer manufacturers. Annual sales exceed $60M with 120 employees. Processes include tube cutting, tube bending, heat treating, CNC machining and robotic welding.

Achieved 100% On Time Delivery for 12 consecutive months.

Presented GKN Presidents Award for development and execution of Kanban Scheduling implementation

Executed plant closure and transfer of assets with no customer impact or degradation of performance. Plant Manager – Estherville, IA (2007 – 2009)

Managed plant operation that manufactures steel wheels to agriculture, mining and construction markets. Annual sales exceed $90M with 200 employees. Processes include stamping, roll forming, mig and sub-arc welding, painting. PULLMAN INDUSTRIES, South Haven, MI 2001 – 2007

Plant Manager (2005 – 2007)

Operations Manager (2001 – 2005)

Managed a Tier 1 automotive facility that manufactures structural components to OEM customers. Annual sales exceed 90M with 300 employees (250 Teamsters Union employees). Processes include stamping (50T – 1000T), roll forming and robotic welding. Customers include Ford, General Motors and Chrysler.

Negotiated labor contract with Teamsters Union.


JOHNSON CONTROLS, Various Locations

Assistant Plant Manager – Shelbyville, KY

Operations Manager – Chesapeake, VA

Production Manager – Kansas City, MO

Welding Department Manager – Ossian, IN

Managed Tier 1 automotive operations that manufacture seats and internal components Just In Time and Sequenced to OEM customers.


Bachelor of Science in Business Management with highest honors Davenport University, Kalamazoo, MI

Associates in Manufacturing Technology, Graduated Cum Laude Indiana Vocational Technical College, Ft. Wayne, IN PROFESSIONAL DEVELOPMENT

GKN Managing Continuous Improvement Leadership

2 Year Lean Manufacturing training program focused on Manufacturing Process, Business Process, and Lean Leadership

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