Operations Manager

THOMAS E. MAYER

716-***-**** ********@**********.***

A performance and quality-driven operations professional, possessing diverse experience in engineering, maintenance, facilities operations, project management, environmental, industrial hygiene, safety and personnel in a unionized, Fortune 500 global automotive manufacturing Company. Responsible for facilities operations at a 3.1Million sq. ft., 190 acre, multi-building and product, 2000+ personnel site manufacturing 700,000 automotive engines and components per year, generating $1.1 billion annually, receiving JD Power and Wards recognition globally.

Demonstrated accomplishments include increasing operations efficiency through resource allocation, cost control, risk management and strategic manpower utilization. A proactive and diligent hands-on leader with proven ability to oversee critical path programs, ability to deliver process and organizational turnarounds, effectively driving change while leveraging outstanding relationships and management skills.

PROFESSIONAL EXPERIENCE

Manager of Facilities Operations

Responsible for the operations, maintenance, regulatory compliance and project implementation, for a 3.1Million sq. ft., 190 acre, multi-building and product manufacturing operation. Functional support of all facilities and utilities operations, environmental systems, industrial and 3rd party services contractors and mobile equipment, to assure seamless 24-7 manufacturing operations support.

Drove reductions in facilities operations budget performance in labor, utilities and 3rd party service provider costs, attaining 5% annual budget reductions 4 years running to a $40M+ annual budget.

Lead energy reductions leading to 4 EPA Energy Star for Industry awards for the facility

Lead expansion of 3rd party Contracted Service agreement providers in industrial services, supplemental skilled trades, and utilities support services, reducing trades headcount by 15% over 4 years.

Implemented strategic utilization of the unionized skilled trades workforce, attaining competitive construction cost levels, offsetting over $3M in outside contracted contractor expenses.

Developed and implemented Best Practice Safety processes for skilled trades workforce, attaining a 3 year running, injury free safety performance

Staff champion for 12 aspects of the sites Safety Management Program.

Responsible for the systemic integration for corporate sustainability policies and initiatives into the manufacturing, maintenance and support operations of the organization.

Advisor to Executive Staff on current status and future corporate and governmental compliance issues.

Achieved annual operating expense budget reductions of over $1M annually through implementation of utility reduction projects and deployment of Alternate Work Schedule for labor cost reductions.

Implementation and integration of Global Manufacturing Systems to both salaried and hourly teams, improving defined work function content through standardized work deployment, promoting job continuity while minimizing effects of manpower turnover.

Direction of plant engineering and project management resources for the installation of an $850M Engine program, integrating a unionized labor team to install engine manufacturing equipment on engine assembly and machining lines.

Executed a $1.3M manufacturing office area modernization project, $2.0M cafeteria and locker modernization project, while providing uninterrupted service to employees.

THOMAS E. MAYER Page 2 ********@**********.***

Superintendent of Manufacturing Engineering

Responsible for the management of the Plant, Electrical and Environmental Engineering Operations, with direct oversight of 45 engineers supporting plant operations

Led development of the facilities 1st Environmental Management System, attaining ISO14001 certification by deployment of procedures and system to support environmental regulatory compliance operations, reducing regulatory compliance issues by 80% over a 3 year period.

Directed the deployment of environmental landfill free initiatives, becoming the 2nd General Motors facility in North America to achieve landfill free status

Lead Negotiations as the staff advisor for local skilled trades for 3 multi-year local skilled trades’ contracts, including the development of strategies for the reduction of 7 skilled trades classifications, reducing contractual complexity, increasing functional trades flexibility and providing long term head count reduction capability, reducing maintenance labor staffing by $2.3M over a 7 year period.

Directed construction management operations for unionized skilled trade’s workforce in support of a $425M, 2-year Site Modernization and Engine manufacturing program.

Plant contact for the development and execution of business expansion grant packages with corporate, local and state and government representatives, securing $88.95M State and Agency grants associated with Engine business expansion.

Responsible for multiple site facility infrastructure improvement projects to support new product expansion programs, including the construction of a 640K sq. ft. manufacturing facility and integral administration office, cafeteria and locker room.

Implemented 2D Matrix part track and trace systems, providing component to assembly traceability history, improving quality containment and assembly traceability initiatives, reducing product sort costs by $250K annually.

Maintenance Manager

Responsible all operations, budget and strategic planning for 900 skilled trades and industrial support service employees, supporting 5 product lines of manufacturing operations, producing 1.6M engines annually

Deployed first database driven, site-wide Maintenance management system, structuring over 5000 annual preventative maintenance tasks, improving uptime and throughput of critical manufacturing and facilities equipment.

Implemented and deployed a 3 shift maintenance operations strategy reducing annual overtime budget by $2.7M annually.

Implementation of predictive technologies strategies focused at increasing uptime by decreasing MTBF and MTTR of critical equipment operations, using Vibration analysis, Infra-red scanning and laser alignment.

ADDITIONAL CAREER POSITIONS

Maintenance Planning Manager, Manufacturing Engineering Administrator, Maintenance supervisor, Engine Component Process Engineering, Purchasing Buyer, Supervisor Tool & Die, Lubricants & Abrasives engineer

Member - Western New York Sustainability Business Roundtable Council

EDUCATION

Masters of Science - Manufacturing Management Bachelors of Science - Mechanical Engineering

GMI Engineering and Management Institute, Kettering University

Flint, Michigan Flint, Michigan

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