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Injection Molding Plant

Location:
Chelsea, Michigan, 48118, United States
Posted:
October 12, 2016

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Expert in manufacturing operations, with a concentration in expanded polypropylene

(EPP) and expanded polyethylene (EPE). Expert understanding of the EPP market in North America. Vast experience in managing operations for multiple molding, assembly, and processing facilities. Thorough knowledge of construction and plant start-up, business marketing, and working with local and state governments. Experienced in product develop- ment for both industrial applications and consumer markets. Summary:

acw0z3@r.postjobfree.com

www.linkedin.com/in/smatherly

1-734-***-****

Consultant on a variety of projects involving engineering, manufacturing, business develop- ment, and product development.

Consultant

Maverick Industries

July 2014 - Present

After selling my business, Maverick Industries, to JSP International, I was employed by JSP during the business transition. Continued to manage operations of our 140,000 sf steam-chest molding facility, continued new EPP/EPE product development, and worked closely with customers. Continued with similar responsibilities as in role of President/GM of Maverick Industries. Managed new construction of additional 40,000+ sf facility and the installation of expansion equipment for cross linked polyethylene foam (XLPE) business launch. General Manager

JSP International

Jackson, MI

August 2011 – July 2014

Owned and managed the operations and business of one of the largest steam chest molding facilities in North America. Developed and wrote strategic business plan for steam chest molding and assembly plant supplying production parts, packaging, and product to indus- trial and commercial markets. Secured financing for facility. Worked with local and state government to secure grants, tax abatements and assistance. Hired and managed professional services for legal, environmental, and accounting services. Developed and tracked budget and timelines. Coordinated start-up of machinery, start-up of production and scheduling systems. Developed plant organizational matrix and systems for organizational development, hired plant staff, initiated training and operating systems. Researched, developed, and established new product lines for EPP and EPE markets. Led and managed new product development activities, product design, and product testing. Identified and developed new customers and managed launch of new products into marketplace using Quality Function Deployment and Voice of the Customer strategies. Developed and coordinated engineering department for product design development. Coached sales staff and representatives in developing customer base and sales approach. Developed customer relationships resulting in business for OEMs including Toyota, Ford, BMW, Magna, Mercedes, and VW and several major Tier One automotive suppliers. Fostered a team environment focused on best practices and process improvements.

President, General Manager

Maverick Industries

Jackson, MI

January 2009 - August 2011

Experience:

Technical Processes:

Steam Chest Molding

Assembly

Injection Molding

(75-3,000 ton)

Structural Foam

Plastic Recycling

Extrusion, Pelletizing

Blow Molding

Extrusion

Thermoset Injection

Thermoplastic Injection

Insert Molding

Gas-Assist Molding

Steam Chest Molding

Thermoforming

Resins:

EPP

EPE

ABS

PC

PP

HDPE

Nylon

PS

TPE

PET

Various

Engineered Resins

Scott Matherly

Launched $21-million steam chest molding and assembly plant supplying the automotive industry (key clients: GM, Ford, Chrysler, Honda, Toyota, Nissan Subaru, Mercedes). Managed plant construction, start-up and product launch. Responsible for establishing scope of work and developing contracts for plant utilities and equipment. Designed plant layout, managed support equipment installation and machinery installation. Developed and tracked budget and timelines. Coordinated start-up of machinery, start-up of production and scheduling systems. Developed plant organizational matrix and systems for organizational development, hired plant staff, initiated training and operating systems. Responsible for iden- tifying plant organizational needs and hiring plant staff. Worked with Michigan Economic Development Corporation to coordinate government incentives and support for plant development. Managed operations of the facility including full P&L responsibilities, budget forecasting, capital improvements and production. Developed and coordinated engineering department for product design development. Oversaw development of CAD data systems, EDI, and internet ordering systems. Coordinated ERP and MRP systems for remote operating facilities. Managed satellite manufacturing facility in California. Managed severe cost-cutting measures and expense control. Implemented lean manufacturing systems, including Six Sigma, Kaizen, Kanban, to meet customer pricing demands. Managed strategic planning efforts for reengineering product and business focus. Operations Manager

Kaneka Texas Corporation

Jackson, MI

Pasadena, TX

San Leandro, CA

Sept 1999 - Jan 2009

Key Processes:

Steam Chest Molding

Assembly

Key Resins:

EPP

EPE

Activities centered around the start-up of a $16-million injection molding and assembly plant. Assumed direct responsibilities for plant construction in Detroit’s Empowerment Zone. Responsible for establishing scope of work and developing contracts for plant utilities and equipment. Designed plant layout, managed plant construction, support equipment installation and machinery installation. Developed and tracked budget and timelines. Coordinated start-up of machinery, start-up of production, and scheduling systems. Developed plant organizational matrix, hired plant staff, initiated training, and operating systems. Responsible for identifying plant organizational needs. Managed operations of the facility, including budget forecasting, P&L responsibilities, capital improvements and production.

Plant Manager

Mexican Industries/Dos Manos

Detroit, MI

Feb 1998 – Sept 1999

Key Processes:

Injection Molding

Assembly

Key Resins:

ABS PC PPO PP

Responsible for plant start-up of a $10 million facility requiring plant construction and building renovation in the Detroit Empowerment Zone for a European-held company. Involved in extensive negotiations with city and state government, involving legal and environmental issues pertaining to brown-site property remediation, site clean-up and government requirements. Managed plant reconstruction, including scheduling and bud- get development, full P&L responsibilities and all phases of plant construction. Responsible for the design and purchase of plant machinery and all ancillary equipment. Managed the start-up of plant equipment and manufacturing operations. Coordinated and implemented information systems for manufacturing scheduling, shipping and receiving, material resource planning and quality control.

Managed operations of custom plastic injection molding and assembled components plant. Plant profile included 240 employees, over $30 million in sales, a first tier automotive supplier with a customer base of automotive and consumer goods. Initial focus on culture change management and plant turn-around. Directly managed department managers, empowering a team environment focused on best practices and process improvements. Coordinated development, budget forecasting, utilization and capacity studies as well as systems implementation. Directly managed two major programs totaling $14 million in sales. Full P&L responsibilities. Established measurables and tracking programs. Responsible for recommending capital improvements and implementation of programs Plant Manager

Perstorp Xytec

Detroit, MI

1996 -1998

Key Processes:

Structural Foam

Key Resins:

HDPE PP

Plant Manager

Sur-Flo Plastics & Engineering

Detroit, MI

1994 – 1996

Key Processes:

Injection Molding

Key Resins:

HDPE PP Nylon

ABS TPE PC P

Engineered Resins

Managed operations of plastic recycling. Responsible for P&L, plant finances and budget forecasting. Directly supervised department managers. Coordinated plant safety efforts. Optimized utilization of production equipment. Participated in research and development efforts of plastic container recycling. Maintained plant sales of finished product. Oversaw purchasing of raw materials, supplies and equipment. Recommended capital improvements and oversaw their implementation. Worked with general manager to develop recycling business plan. Managed special projects.

Responsible for machinery installation at plant start-up. Responsible for production and support machinery in plant. Hired and supervised plant maintenance department. Established and supervised the quality assurance department. Designed layout of and installed production machinery. Designed and implemented improvements to production equipment. Managed and maintained EPA records and correspondence. Established preventative maintenance program. Established spare parts policy and failure analysis program.

Plant Manager

Johnson Controls, Inc.

Plastics Technology Group

Novi, MI

1992-1994

Plant Engineer

Johnson Controls, Inc.

Plastics Technology Group

Novi, MI

1990 - 1992

Key Processes:

Plastic Recycling

Extrusion, Pelletizing

Injection Molding

Blow Molding

Key Resins:

PET, HDPE, PP

Master of Science

Operations Management

Lawrence Technological University

Southfield, MI

GPA 4.0

Institute of Electrical and Electronic Engineers (IEEE) National Fire Protection Agency (NFPA)

Blow Molding

Extrusion

Thermoset Injection

Thermoplastic Injection

Structural Foam Molding

Insert Molding

Society of Plastics Engineers (SPE)

Project Management Institute (PMI)

ISO 9000

MRP

Training the Trainer

QS 9000

PMP

TS16949

JIT

SAP

TQM

Kanban

EDI

Kaizen

Bachelor of Science

Electrical Engineering

Lawrence Technological University

Southfield, MI

Education:

Memberships:

Technical Processes:

Quality Function Deployment

Lean Manufacturing

House of Quality

Six Sigma

Voice of the Customer

Project Management

Project Management Professional

Gas-Assist Molding

Steam Chest Molding

Thermoforming

Class 3 Boiler Operator license operator

Experience in cooling water

and boiler water treatment



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