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Injection Molding Plastic

Danville, Kentucky, United States
October 13, 2016

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Douglas N. Thornburg, II

**** ******* ******* ** ********, KY 40484 859-***-****



Accomplished leader with experience in all aspects of plant operations including: Injection Molding, Tooling, Production, Materials, Logistics, Quality Assurance, Human Resources, Engineering, and Maintenance. Experienced with implementing QS/ISO 9000, TS 16949 and ISO 14001 management systems as well as Lean Manufacturing concepts. Results oriented, decisive leader with proven success delivering outstanding productivity and quality improvements while implementing significant cost cutting solutions. Responsible for leading and mentoring cohesive, productive teams and structuring operations.

Core Competencies

Green Belt Six Sigma

Injection Molding Tooling Assembly

Lean Concepts ISO & TS16949 Professional Leadership

Customer Relations Bilingual (Spanish) Class “A” Surfaces

KanBan Inventory System Product Launch Program Management

JIT Troubleshooting Maintenance

Career History

Spirit Manufacturing, Inc – Lexington, KY 3/2014 – Present

Vice-President of Operations

This facility is a plastic injection molding facility with locations in Clearwater, FL and in San Antonio, TX.

We specialized on not only the production but the design of products for the agricultural industry. I am personally

responsible for all MP&L, planning growth, setting new goals for the company, while always monitoring the

bottom line. I am also responsible and monitor all day-to-day activities such as customer relations, supplier relations, and all internal management relations.

Key Achievements

Scheduling all growth

Overseen two new product lines, from conception to production

Training all department managers for a Lean environment

Successfully launched two new product lines

Assisted in the marketing of new innovative products

MAGNA – Detroit, MI/Saltillo, MEX 5/2013 – 3/2014

Plant Manager

Plastic injection molding facility for automotive industry

This facility is a plastic injection molding facility and sub-assembly plant. At this facility, I am responsible for a 7 million dollar expansion. This expansion includes upgrades to the facility, purchase of new equipment, installation of plastic injection molded presses, installation of all material conveying systems, installation of water systems, and maintaining correspondence will all contractors to maintain a schedule for implementation of plastic injection molding. I am also responsible to perform the same expansion in Mexico along with implementing continuous improvement projects and minimizing quality concerns, while optimizing the manufacture of plastic injection molded parts for the automotive industry.

Key Achievements

Maintaining the expansion budget, while maintaining the scheduled start

Create relationships at other divisions for customer service (Chrysler)

Train operators to injection molding processes (ie: first point of inspection)

Minimize cycle times to increase machine capacities

Create relationships with vendors for injection molding

Transnav Technologies – Danville, KY 10/2012 – 3/2013

Plant Manager Reason for Leaving: Company Changed Ownership

Plastic injection molding facility for automotive industry

In this position, I was responsible for the day to day operations of the entire facility, which includes shipping/receiving, materials, production, assembly, quality, maintenance, tooling, and P&L. I also worked closely with the customers with any new upcoming projects or any existing issues. I also assisted with creating and implementing quality standards for the TS certification that is required by the automotive industry. This facility manufactures Class “A” surface parts for the automotive industry.

Key Achievements

Cross-train operators to not only work in molding but have the ability to work in assembly

Reduction of manning for lean operations

Assisting in implementing a Quality System

Increased profits by 20% within the first 60 days

Reduced downtime and scrap by 30% within the first 60 days

Daiei America, Inc. – Murfreesboro, TN 2/2012 – 10/2012

Production Manager Reason for Leaving: Advancement In Career

Plastic injection molding facility for automotive industry

In this position I was responsible for all three shifts of manufacturing. I managed all three shifts through Shift Supervisors. I set the production schedule, machine downtime schedule, and tooling downtime schedule, based on the customer production requirements. I was responsible for creating and implementing ISO standards for all of production. I completed writing Procedures, Policies, and Work Instructions for QS manual. I was also responsible for the secondary equipment (assembly). This facility manufactures Class “A” surface parts for the automotive industry.

Key Achievements:

Create all training documents for new Operators, Material Handlers, Mold Techs, and Processors

Create all procedures for work flow throughout the production floor

Assisting in the implementation of an inventory system, which will allow for a more efficient schedule of production

I began at this facility when it was operating only one shift and after 4 months I have been able to train, schedule, and develop all three shifts to be fully operational

Reduced cycle times on all machines to minimize any overtime and created time for scheduled maintenance

Contract Consulting 1/2010 – 2/2012

Consultant for Injection Molding/Tooling

Plastic injection molding facilities for automotive industry

I was responsible for implementing lean processes throughout the facility, cross-training staff, reducing manpower, and increasing profits without increasing overhead. These facilities specialized in automotive parts. Parts consist of air inlet panels, wheel liners, and bumpers. The equipment is all automated utilizing robotics and varies from 1100 ton presses to 2750 ton presses. This required the knowledge of tooling and manufacturing, which assist in troubleshooting. I also created the schedule for all three shifts of production to minimize overtime.

Key Achievements:

Trained Maintenance on Tooling Repair and Preventative Maintenance

Reduced cycle time with tooling modification

Cross-trained operators to operate efficiently at all work stations

Improved Tooling to increase efficiency and utilize all available press time

Reduced manpower on a production line from five operators to four operators while maintaining quality

Technology Molded Plastics – Decatur, AL 10/2005 – 12/2009

Plant Manger Reason for Leaving: Company Closed

Multi-Site Plastic Injection molding facility for automotive industry

I was responsible for tracking all production, delegation of work, scheduling, and implementation of quality control standards (ISO/TS) that are required by the automotive, aerospace, and medical industries. I spent a portion of my time on the floor daily determining where improvements in employment and machine capabilities could be made. The presses that were being operation were Toshiba, Van Dorn, and Cincinnati from 40 ton to 3500 ton capacity. The end product consisted of bumpers, facias, door panels, and wire housings. By being hands-on in this position, I was able to assist in troubleshooting, training, and preventative maintenance, which enabled TMP to cut additional overhead cost.

Key Achievements:

Within the first six months, I was able to take production from 60 employees with 70% efficiency to 45 employees producing at a rate of 85% efficiency.

Reduced overhead cost by 15% by cross-training

Lead a team of people for an expansion, which included adding a new facility, additional machinery that minimized manpower, while following a budget of approximately 8 million dollars, created the schedule for implementation, and met the scheduled date of start.

Reduced cycle time by modifying tooling to allow for faster cycles, while maintaining quality of part

Improved customer relationships

Vision Tool & Die, LLC – Tuscumbia, AL 8/1995 – 1/2005

Plant Manager 1/2003 – 1/2005

Reason for Leaving: Company Closed

Vision Tool & Die manufactured plastic injection molds, die-cast dies, and precision machined parts for the automotive, defense, aerospace, and medical industry

This position was responsible for production, delegating work throughout the entire plant to ensure on time deliveries. I was very hands-on in managing machine-time, training employees on machinery capabilities, and assisted on the shop floor. I utilized software such as Mastercam and Cadkey for programming and blueprints. I assisted in on-line and off-line programming. The equipment used in this process was CNC mills and CNC lathes with Centroid controls. I was responsible for the quality of all work performed, customer support relations, and delivery dates.

Shift Supervisor 5/1998 – 1/2003

In this position, I assisted in training new machinist, scheduled machine time, assisted in quotes, and also worked as the lead tool and die maker. I was responsible for the build of plastic injection molds and die-cast dies.

Machinist 8/1995 – 5/1998

In this position I was trained to operate and set-up manual milling machines, CNC milling machines, manual lathes, CNC lathes, manual surface grinders, hydraulic surface grinders, electrical discharge machines, operating forklifts, operating cranes, reading blueprints, and developing new blueprints for the purpose of machining. I became proficient at operating all machines and proficient at reading blueprints.

Key Achievements:

I have been able to work from the ground floor as a machinist up to plant management. The experience that I have been able to attain on the floor in manufacturing has assisted me in my development as a manager and allows me to communicate from the front office to the plant floor.

I am able to understand the process and responsibilities of each position in the company. By understanding these processes and responsibilities, I am able to keep cost down and quality up.

I enjoy problem solving and training new employees


Machine Safeguard, OSHA, & ANSI Training 2014


Six Sigma 2012

Green Belt

Bachelors Degree

University of North Alabama 2001

3.5 GPA – BS – Business Management

Microsoft Certified Systems (Office Suite) 2000


Microsoft Certified Networking Systems 2000


Associates in Applied Science

Northwest-Shoals Community College 1999

3.5 GPA – A.A.S. – Computer Information Systems

High School Advanced Diploma 1996

Cherokee High School

Advanced Diploma

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