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Manager Plant

Lenoir City, Tennessee, 37771, United States
October 16, 2016

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Ed Hagerdorn

*** ********** **.

Lenoir City, TN 37771



Versatile operations leader with a strong track record of successful implementations of world class manufacturing processes, lean operating disciplines, and profit generating initiatives. Creative problem solver and change agent with a strong work ethic. A leader who demonstrates commitment with a lead by example style and engages team members with a participative team approach. Successful in providing the highest degree of customer satisfaction and quality performance through continuous improvement efforts. Champion, leader, and facilitator of employee involvement, kaizen, value stream mapping, employee safety, cycle time reduction, standard work, line balancing, Kanban, SPC/six sigma, Shainin problem solving, supply chain optimization, setup reduction, cellular manufacturing, ISO/TS/AS and NADCAP requirements, C2C, and policy deployment.


AE Group Inc., Knoxville, TN 37922

The AE Group is the ownership group of HVACR companies in Knoxville serving private and commercial heating, ventilation, air-conditioning, and refrigerant.

Operations Manager and Leadership Coach Dec 14 – Present

Reports to the owners of the company. Manage day to day operations of the service and installation groups at Aire-Serv Knoxville.

Developed business plans to double the size of the business organically in three years.

Installed new ERP system that consolidates three, previously separate, software systems and integrates the business from job scheduling through real time KPI reporting.

Grew top line revenue by 22% by growing maintenance customers by 28% over the past 13 months.

Grammer Inc., 231 Laney Rd, Tupelo MS 38868

Grammer AG is a German based publicly traded company supplying seats, consoles, and other interior components to the automotive, heavy duty truck, and off-road OEMs.

Transitional Plant Manager Jul 14 – Dec 14

Reports to the Vice President of Operations and Vice President of Product Market Segments. Grammer Tupelo is a startup operation transferring assets and production processes from Hudson, WI. P&L responsibility for one non-union facility, employing 67 hourly and 22 salaried employees. Processes include foaming, assembly and warehousing. Reporting to this position are a Controller and managers of HR, Industrial Engineering, Logistics, Production, Quality, Purchasing and IT.

Successfully passed five customer system audits and two product quality audits within the first 70 days of operations.

Led the project management team and moved five production cells and support processes on time and in budget.

Led the training program that certified all new operators to produce Grammer products faster than the project plan. Recognized by the BoD for project success.

Enginetics Aerospace, 7700 New Carlisle Pike, Dayton OH 45424

Enginetics Aerospace is a $29M supplier to the aerospace sector and is owned by Morgenthaler Private Equity (MPE).

Senior Vice President of Operations Feb 13 – Jan 14

Reports to the CEO. Enginetics produces complex formed sheet metal engine components and sub-assemblies for the aerospace industry. P&L responsibility for two non-union facilities, employing 137 hourly and 24 salaried employees. Processes include stretch forming, hydroforming, laser cutting, traditional machining, EDM, welding, heat treating, and assembly. Reporting to this position are Vice Presidents of Engineering, Manufacturing, and Quality and a Plant Manager.

Took a six gate new part introduction process that was overwhelmed with the introduction of over 60 parts in 2013 and added date and cost milestones and established a weekly review meeting to track progress.

Established metrics at the cell, plant and business level to measure team and business performance and identify opportunities for improvement.

Justified and gained approval for a $1.0M investment in a servo press to further the business’ stretch forming capabilities.

Reduced the OSHA recordable rate to 1.9 in our Huber Heights facility and reduced it from 16.2 to 11.1 in the Eastlake facility.

Precision Castparts Corp, Hackney Ladish, 3900 Elmira, Russellville AR 72802

Hackney Ladish is an $81M division of Wyman Gordon Forged Products whose parent company is PCC, a $7.2 billion global supplier to the aerospace and energy markets.

General Manager Apr 10 – May 12

Reports to the Vice President of Wyman Gordon Operations. Hackney Ladish specializes in the hot and cold forging of fittings for the energy and petrochemical sectors. Full P&L responsibility for three facilities (one union, two non-union), employing 232 hourly and 31 salaried employees. Processes include open die forging, hot forming, heat treating, machining and finishing. Reporting to this position were Plant Managers, Controller, and Managers of Supply Chain, Quality, HR, IT, and Sales.

Grew the top line from $46M to $81M through a significant restructuring of our product offering and alignment with customer demand.

Improved EBIT by 13 points through a combination of pricing strategies, efficiency improvements, and material cost reductions.

Developed a strategic sourcing plan for raw materials which reduced costs by an average of 14%, removed $8.1M from inventory, and took 22 days out of product lead-time.

Drove the OSHA recordable rate down from 8.2 to 4.1 toward a goal of an accident free career.

GKN Aerospace, 1150 West Bradley Ave, El Cajon, CA, 92020

GKN Aerospace is $2.2 billion division of GKN PLC, an $8.3 billion global supplier to the automotive and aerospace markets. The El Cajon facilities specialize in lightweight chemically-milled titanium and aluminum alloy parts for engines, airframe structures, and launch vehicles.

Vice President and General Manager Dec 07-Jan 09

Reports to the President and CEO of the Propulsion Systems Division. Responsible for the total value stream within a fully integrated ERP environment. Full P&L responsibilities for a highly engineered product line across two facilities (one U.S., one Mexican). Led 678 employees in a non-union environment with annual revenues of $149 million. Processes include roll forming, turning, five axis machining, chemical milling, welding, super plastic forming, and assembly of complex, structures for the aerospace industry. Three Business Unit Directors, Directors of Engineering, Human Resources, and Quality and managers of Lean, Maintenance, and Supply Chain reported to me.

Led the transition of the Mexico operation to a new, larger, facility.

Added employee involvement to the suite of continuous improvement activities that helps to engage employees at all levels of the organization.

Removed $6.1 million of fixed costs; establishing a more competitive position in our industry, and increased EBITDA by $1.3 million.

Reduced inventory by $9.8 million, increasing turns by 33% through a focused reduction of manufacturing lead times.

Developed an in-sourcing plan that brought in $1.8 million of absorption benefit in 2009.

Commercial Vehicle Group, 5700 Perimeter Drive, Dublin, OH, 43017

The Global Truck Division of CVG is a $698 million division supplier to the heavy duty truck and marine OEM markets.

Director of Operations May 05-Dec 07

Reports to the Vice-President of Operations for the Global Truck Division. Full P&L responsibilities for six facilities with 760 employees in both union and non-union environments. Processes include injection molding, thermoforming, reactive injection molding, 3D and 2D molding, cut and sew operations, and sequencing in a JIT environment. Five Plant Managers report directly to this position.

Performed the due diligence and initial integration activities of a $6.2 million acquisition.

Successfully transitioned five of the facilities to ISO/TS 16949 certification.

Established labor performance metrics for the division and standardized production reporting.

Developed ISO 14001 certification plans for all facilities.

ArvinMeritor, Inc., 2400 Maremont Parkway, Loudon, TN., 37774

ArvinMeritor was a $7 billion dollar global supplier of parts and modules to the automotive and heavy duty truck markets. The Loudon operations were a $132 million business which provided exhaust products to the OEM, retail, and installer markets. The Pulaski facility was a $93 million business and provided ride control products to the specialty and export markets.

Director of Operations (Loudon, TN Facility) Apr 01-May 05

Reports to the Vice-President and General Manager of the Light Vehicle Aftermarket, Exhaust Division. Manage manufacturing and distribution operations at three sites in the East Tennessee area, with 580 union employees. Processes include stamping, tube forming, tube bending, wire forming, assembly, and welding. There are seven managers that report to this position.

Re-aligned plant capacity and achieved a six-month cost savings of $.9 million.

Led a strategic sourcing project that produced outsourcing savings of $1.4 million and in-sourcing savings of $445,000.

Introduced Value Stream Mapping events that created $1.9 million in savings.

Implemented a Shainin/Six Sigma process that reduced tube mill scrap by 50% and muffler scrap by 15%. Direct EBITDA improvement of $1.2 million a year.

Led the start-up of a 165,000 square foot, 6,500 SKU satellite distribution center.

Plant Manager/Director of Operations (Pulaski, TN Facility) May 99 – Apr 01

Reports to the Vice-President of Operations. Charged with overseeing the operation of all manufacturing and distribution functions of a 340 member, non-union, organization producing ride control products for the automotive aftermarket. Manufacturing processes include, CNC machining, precision grinding, broaching, plating, painting and final assembly. Four managers and three business unit managers report to this position.

Removed a layer of management and reduced salaried manning by 20%.

Reduced finished goods inventory by 22% through an aggressive changeover reduction program that also improved turns from 9.4 to 10.3.

Led the closure of the facility and the relocation of operations to Mexico.

Tenneco Automotive, Highway 15 South, Seward, NE 68434

Tenneco Automotive is a $3 billion global supplier of exhaust and ride control products to the OEMs and aftermarket channels. The Seward facility generated $123 million in sales.

Production Manager Sep 94 – May 99

Reports to the Plant Manager. Directly responsible for the manufacturing function of a 565 member non-union team. Scope of responsibilities included manufacturing, safety, and continuous improvement. Three managers and thirteen supervisors report to this position.

Project manager for a $23 million acquisition, managing a $4.7M integration budget.

Championed the start–up of an employee managed safety observation program. Total case rate reduced by 16% and lost times accidents cut in half.

Led ISO 9001 and QS 9000 certification efforts – certified in our first audits.

Established the Kaizen program, netting $490,000 in savings in 12 months.

Pedersen Power Products Inc., 3900 Dahlman Ave., Omaha, NE. 68107.

Pedersen Power Products is a $28 million dollar manufacturer of switchgear and relay panels sold to utility districts, governments, and large industrial consumers.

Plant Superintendent Dec 92 – Sep 94

Report to the Vice-President of Engineering and Manufacturing. Responsible for production, quality, maintenance, and shipping. Six supervisors report to this position.

Created the preventive maintenance program, Eliminated two WIP inventories valued at $145,000, developed and implemented the quality standards manual. Started employee involvement and the company’s CI strategy.

United States Air Force Jun 80 – Jun 92

Stationed in California, Korea, England and Nebraska. Held a Top Secret/SCI clearance.

Maintenance Control Supervisor, Quality Assurance Supervisor, Safety Manager, Bench and Field Electronic Technician


MBA, University of Tennessee, Knoxville, TN, 2005

BS Industrial Technology, Southern Illinois University, Carbondale, IL 1992

AS Electronic Technology, Community College of the Air Force, Maxwell, GA, 1991

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