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Plant / Production Managment

Wetumpka, Alabama, United States
October 02, 2016

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Robert Thomas Lumpkin

**** ******** ****

Eclectic, Alabama 36024

334-***-**** Residence

334-***-**** Cell

Deliver dramatic results in the leadership and turnaround of poorly performing organizations.


Business Development Operational Leadership Startups Performance Optimization

Performance-driven and solutions focused Management Professional, successful in leading complex, large-scale businesses and projects across a variety of industries. Rich mix of business development, administrative, and fiscal accountability. Diverse background of experience driving new business startups, operational turnarounds, and rapid growth enterprises. Expertise in resolving long-standing problems and creating solutions that improve performance and operational efficiency. Leverage expert analysis and insights to drive continuous process improvements, utilizing Lean concepts. Lead by example and empower teams to deliver organizational improvements and best practices.

Operations Management

Strategic Planning

Change & Project Management



Continuous Process Improvements

Cost Reductions

Team Leadership & Development

New Business Development




Distribution & Logistics

Inventory Management




Vendor Relations

Assembly Automation


OSHA/Regulatory Compliance

Process Control



Audits & Budgeting

Cost Accounting

Cost/Benefit Analysis

Expense Control

Financial Analysis

Financial Statements

Internal Controls



SL Alabama Alexander City, Alabama 2013-Present

Global Manufacturer of Automotive Headlamps, Tail lamps and Mirror assembles.

Production Manager

Manage the scheduling of the Pre-Production and support the Assembly of injection molded components of forty four injection mold presses ranging from two hundred to thirteen hundred ton machines. Molded components are then transferred to metallization processes via robot to one of five cells. Metalize process is performed using Mustangs, Polments and 4V’s. Components are then packaged and stored in WIP areas ready for Assembly department. There are twenty five assembly lines pulling components from WIP storage. Pre-Production must maintain a one day inventory of hundreds of different components to satisfy Assembly needs. On the Assembly side I am responsible for insuring lines meet quotas for next day deliveries. I support the communication between all departments Pre-Production, Assembly, Quality, Maintenance, Coating, Engineering, Tooling and Human Resources. I am currently mentoring floor Supervisors and Team Leaders in non confrontational management techniques, leadership skills and team building. Continual improvement programs focus on KPI goal achievement using 5S, LPA, PFEMA, CFT and TFT development and monitoring of process application. SL Alabama currently employees approximately eight hundred Associates at this location.

Key Projects and Accomplishments:

I have had a direct impact in the reduction of production days from seven to five for seventy five percent of work cells.

Have been instrumental in improvement of moral and communication between work cells and shifts.

Overall quality improvement and production increases for overall production have been recognized by Plant Manager and President.

MES accuracy improvement and inventory reduction achievement of 1.2 days on hand.

Lead Lean DMAIC training and implementation. KPI monthly goals and 5S standards have been achieved and maintained.


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Hercules Poly Eclectic, Alabama 2006-2013

Manufacturer of polyethylene packaging for Food, Retail, Banking, Judicial and Medical industries.

Plant Manager / Engineering Manager

Hired to turnaround poor performance and mismanagement following an acquisition and act as the President’s “right-hand man.” Rebuilt the infrastructure to bring the facility into OSHA compliance and improved the bottom line. Challenged with analyzing P&L, profit margins, and production processes to evaluate the viability of current operations and made recommendations for improvements to the Board of Directors. Authored new policies and procedures and established quality assurance programs, building the infrastructure from the ground-up.

Hold P&L accountability and administer a $3.5 million budget. Direct leadership for up to 50 employees in daily production activities, ensuring adequate training to boost quality and safety initiatives. Spearhead capital improvement investments of up to $2 million, researching and identifying equipment needs. Cultivate and nurture vendor relations to obtain best price. Track costs and streamline inventory, collaborating with the sales staff on costing programs.

Key Projects and Accomplishments:

Orchestrated a major production improvement process, purchasing and implementing over $3 million in new technologies and establishing procedures for inventory and bill of material. As a result, significant gains in quality, output, and profitability were realized and the payroll budget was reduced by one-third.

Dramatically reduced the maintenance budget $500,000 by identifying disposable tooling and predictive stock needs to support production schedules. Slashed downtime through the establishment of a preventative maintenance program.

Conceived, developed, tested, and implemented a new product line, which delivers over $1.2 million in annual revenue.

Drove relocation efforts of an acquired company to Alabama. Managed the removal, shipment, and setup of all assets and raw materials and spearheaded upgrades to the Alabama plant to accommodate the new equipment.

Slashed lead times by 75% and improved efficiencies by 50%.

Reduced operational losses by $900,000 over four years.

Project managed the expansion of the company to a new location leading equipment removal and setup.

Southern Shutter Montgomery, Alabama 2004-2006

Sales and Installation

Accepted position with company to honor non competitive clause of employment contract with previous employer. Managed installation and sales activities, driving $20 million annually and led territory expansion efforts.

Langcourt LTD Auburn, Alabama 1999-2004

Global manufacturer of reconditioned performance engine cylinders.

Plant Manager

Brought on board to eliminate production and quality performance issues, keeping the company from closure and improving its reputation in the industry. Led staff training to boost quality and safety and established a preventative maintenance program to enhance equipment performance. Streamlined and improved manufacturing and operations, reengineered product flow, and established EPA approved procedures for the disposal of hazardous waste. Recruited, trained, and developed up to 15 employees. Led a community outreach program to teach potential employees needed skills that benefited all the local businesses.

Key Projects and Accomplishments:

Tripled production output within one year and improved turnaround time to the customer from three weeks to five days through the introduction of Lean methodologies and new production philosophies.

Increased sales by $400,000 annually through the development of an amateur racing team, which promoted the company’s services at the track and at convention expos.

Reengineered antiquated hones for increased production capacity. Installed modifications for an auto-turning lathe. Developed in-house diamond tooling resources, capturing a savings of $25,000 annually.

Established a strategic relationship with Yamaha Motorsports to develop a warranty program that drove $200,000 in revenue.

Led advanced machining and production techniques classes to advance staff proficiency and teamwork. As a result output and quality improved by 50%.


Jimco Manufacturing, Inc. Montgomery, Alabama 1996-1999

Field Supervisor

Oversaw the manufacturing and installation of architectural millwork and fixtures supporting the health care and retail industries.

Tom’s Tops, Tallassee, Alabama 1991-1996


Established this custom casework and millwork company, leading all daily activities, including estimating, design, sales, manufacturing, and quality control.

Orchestrated the successful sale of the company to Jimco Manufacturing.

Precision Designs, Inc., Eclectic, Alabama 1986-1991

Production Engineer

Led production team, produced shop drawings, and oversaw quality control. Built fixtures and designed custom tooling, programmed CNC machining centers and screw machines. Customers included Neptune, Bush Hog, Diversified Products, GKN Westland Aerospace and Dana.


Applied Technologies John Paterson Technical College, Montgomery, Alabama

Advanced factory training for world-class equipment, including Hitachi Seki, HAAS, Mazak, Warner Swayze, SCMI, Roll-O-Matic, ROAN, Video Jet, Markem Image, etc.


Windows MS Office QuickBooks Enterprise Suite 11 Adobe Illustrator MES, SWS

Various Peripherals and Networks

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