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Plant Manager

Location:
Buford, Georgia, United States
Posted:
October 02, 2016

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JOHNNY MORETTI

770-***-**** / **** Griggs Ct., Buford GA 30518 / acwvn1@r.postjobfree.com

LinkedIn Profile: http://www.linkedin.com/in/johnnymoretti

SUMMARY

Bilingual Industrial Engineer & MBA with expertise in Operations (Project Management, Supply Chain, Quality & Manufacturing).

Responsible for multi-facilities operations, including direction & control of buildings, equipment, materials, transportation & labor, along with start-ups, implementations & maintenance.

Managed several projects in different platforms (ERP, SAP, Oracle, AS400) & systems (Microsoft Office, Project, Visio, SharePoint, Lotus Notes). Able to meet/exceed KPI's goals.

Responsible for Quality (TQM), Maintenance (TPM) & Continuous Process Improvement (Kaizen, DMAIC - Six Sigma, Lean), mainly focused on Customer's satisfaction (CRM), services & products.

Managed audits, inventories & prepared control reports (SPC). Run quality metrics & programs to identify corrective action plans & records.

Managed Supply Chain (WMS) migrations & negotiated contracts with Suppliers & Vendors looking to reduce costs & improved services.

In charge of Environmental-Health-Safety (EHS) OSHA Compliance, Hiring & Cross-Training Committees. Safety Champion & Member of the Capital Equipment Board.

ACCOMPLISHMENTS

Meet established EBITDA Targets and annual volume target 81.8 million units.

Obtain 90% weekly WO/units attainment and improve Shift Reliability Rate by 10%.

Started up company & developed a website to market business & improve customer’s database increasing sales by 25%

Measured goal achievements keeping productivity standards at 95% average & reducing costs by 30%

Drove Productivity to become #1 Plant out of 110 locations corporate wide

Controlled daily operations, including work force requests to improve productivity, efficiency & customers’ satisfaction exceeding corporate quota by 15%

Managed Distribution Centers operations, quality control & supply chain increasing revenue by 20%

Negotiated & improved suppliers & carriers contracts reducing costs by 25%

Developed & implemented a turnkey Electroplating process improving quality products by 75%

Negotiated new capital equipment & improved purchasing research reducing costs by 20%

Planned & controlled of Operations Division increasing revenue by 25%

Carried out a MRP system for auxiliary materials & parts, avoiding losses & reducing costs by 25%

Optimized production systems & Just-in-Time (JIT) inventory, increasing molds lifetime by 40%

PROFESSIONAL EXPERIENCE

KIK CUSTOM PRODUCTS, INC - Gainesville GA; 04/2014 - Present

(Privately Held; ~350 employees - #1 Contract Manufacturer for the Consumer Packaged Goods industry - CPG).

Production Manager - Managed the day-to-day operations, reporting to the General Manager.

Meet established EBITDA Targets and annual volume target 81.8 million units.

Obtain 90% weekly WO/units attainment and improve Shift Reliability Rate by 10%.

Ensure adherence to defined quality, GMP & safety standards.

Train and coach team to meet defined productivity targets.

Assist with identifying & implementing process improvement initiatives.

Preview production & operating reports & resolve operational manufacturing & maintenance problems to ensure minimum costs & prevent operational delays.

Develop & work with supervisors/line leaders in all areas such as problem solving, setting & achieving goals, manufacturing processes, scheduling & equipment problems

Partner with Engineering/CI to improve the manufacturability of products.

Provide technical support to shop operations in the areas of equipment, layout, tools, fixtures & machines to ensure low-cost & high-quality products.

Encourage & promote a plant culture of Continuous Improvement & Employee Involvement.

ALTERNATIVE BEST CLEANING, LLC - Buford GA; 03/2010 – 03/2014

(Privately Held; ~80 employees - Janitorial Service Provider Specialized in Commercial & Industrial Cleanup)

Pro Air Care, LLC. - Sister Company (Air Duct Cleaning Service Provider).

Operations Manager - Managed the day-to-day operations, reporting to the CEO.

Started up company & developed a website to market business & improve customer’s database increasing sales by 25%

Provided overall leadership in operational performance & supply chain in the facility & property management markets.

Measured goal achievements keeping productivity standards at 95% average & reducing costs by 30%

Oversaw sales & marketing functions, including key accounts management, customer relationship development & contract negotiations.

Negotiated materials prices with suppliers & coordinated inventory control programs.

Built & developed facilities network system. Acted as liaison between Facility & Project Managers.

Determined staffing requirements, hired & trained new employees. Prepared SOP's, work schedules & assigned specific duties.

Coordinated & perform facilities' inspections. Identified & corrected potential hazards to ensure OSHA regulation compliance.

Implemented environmental sustainability programs regarding recycling, conservation & waste management.

G&K SERVICES, INC - Buford GA; 03/2007 - 02/2010

(Privately Held; ~8K employees - Nationwide Market Leader in Branded Identity Apparel Programs & Facility Services.)

Production Manager - Managed the day-to-day operations, reporting to the Plant Manager.

Drove Productivity to become #1 Plant out of 110 locations corporate wide

Controlled daily operations, including work force requests to improve productivity, efficiency & customers’ satisfaction exceeding corporate quota by 15%

Recruited, developed, retained & fostered a diverse workforce maximizing team performances while maintaining high ethical standards & reducing turnover by 25%

Managed operations budget financial viability & facilitate scheduling of preventive maintenance program, repairs & projects achieving 100% of corporate goals.

Developed planning documents for equipment replacement & repairs for approval. Inspected completed work assignments to ensure satisfactory work quality.

Maintained established systems & training programs to provide a safe working environment. Comply with all OSHA regulations & other local, state & federal government regulations. Plant reached 100% compliance in all safety & cross training activities.

FLAMBRO IMPORTS, INC - Atlanta GA; 03/2001 - 02/2007

(Privately Held; ~180 employees - Importer & Wholesaler Nationwide Distributor Specialized in Home/Office Décor & Furniture)

Operations Manager - Managed the day-to-day operations, reporting to the CEO.

Managed Distribution Centers operations, quality control & supply chain increasing revenue by 20%

Negotiated & improved suppliers & carriers contracts reducing costs by 25%

Developed & implemented e-Catalogs improving on-line sales by 15%

Carried out a major retailers VendorNet B2B systems; i.e. Home Depot, Neiman Marcus, Amazon, QVC, Federated Department Stores, Orvis, NetShops.

Designed & administrated a website providing customer’s access to re-designed digital catalogs & brochures improving web traffic by 90%

Formulated & implemented company reports system reducing costs by 20% & optimizing forecast analysis by 75%

CARLO MARIO CAMUSSO, INC - Lima PE; 02/1996 - 01/2001

(Privately Held; ~200 employees - Latin American Market Leader in Sterling Silver Products, "Transforming Silver in Art")

Technical Manager - Managed the day-to-day operations, reporting to the Director of Operations.

Developed & implemented a turnkey Electroplating process improving quality products by 75%

Negotiated new capital equipment & improved purchasing research reducing costs by 20%

Trained & supported Sales Reps. technical skills to solve customers’ requirements.

Reserved materials, WIP & finished goods to support production, supply chain & customer relationship.

Optimized manufacturing processes reducing operations costs by 15%

Managed inbound/outbound of products, parts & accessories ensuring timely deliveries to maximize sales.

EDUCATION

Master in Business Administration (MBA), ESAN University - Major: Management - Graduated Top 20%

Bachelor of Science in Industrial Engineering (BSIE), University of Lima - Major: Manufacturing & Logistics - Graduated with Excellency - Chairman of Industrial Engineers

1st Class Midshipman, Naval Academy of Peru

Bilingual in English & Spanish. Fluency in Italian.

IT Skills: MS Office Pro. Lotus Notes. MS Project, Visio, SharePoint, FrontPage. Windows Vista, XP, NT. HTML Protocol. Peachtree, QuickBooks. QRS, eBrandwise, Boomerang. Hardware & Networking Installation. Distribution 2000 (D2K-SBClient). VendorNet B2B Sys. AutoCAD. Adobe Photoshop, Illustrator. SAP, PeopleSoft. WMS + UPS/FedEx Interface.

PROJECTS

STAIN AUDIT PROJECT (Sydney, AUS) – November 2013 to Present

Hired by Millennium Mats to represent them in Australia as an Independent Consultant to evaluate a stain issue at Coles Supermarket Stores; apparently related to the 17,000 brand new floor mats shipped from Atlanta and installed by Alsco in Australia nationwide within the last 3 months.

PRODUCTIVITY IMPROVEMENT PROJECT (Buford, GA) – March 2009

Kaizen project started back in March of 2008 when the Buford plant was ranked 44th out of about 110 locations. We decided to become the #1 plant and put in place a six-month plan to excel the current corporate production standards.

We started by meeting with the whole plant associates to explain the program in detail. Then, we worked with the team leaders to standardize each activity, along with the target and how to measure them all. Due to ninety percent of the associates being Hispanic, we translated all SOP's to make sure they clearly and completely understand everything.

At the end of the 2nd quarter, our productivity improved by ten percent, and thanks to the aggressive cross-training program we put in place the year before, three months later, we were flying at almost thirty percent improvement. Results were so good that we had to re-adjust several standards. Buford was recognized as plant #1 in March of 2009!

WMS MIGRATION & IMPLEMENTATION PROJECT (Atlanta, GA) – March 2003

It certainly was one of main projects I have led. The company had in place an old version of a SBClient package. Despite of not being Windows friendly, which it did not allow us to export any data into Excel; it lacked of other essential features as well; like not being able to interface with the UPS shipping and labeling system.

Based on all of these facts, we decided to migrate to a new WMS system. Therefore, I led the entire project and worked with the technicians, from the model conception by developing a detailed map of the business processes with flow diagrams, to the coordination with all of the department heads affected by the new system (Accounting, Order Management, Sales, Customer Service, etc.).

Also, I was involved during the configuration and testing. We determined the features to be implemented, and organized the input of parameters and data. I was the designated company Trainer and I was also part of the Support Team. Finally, I was in charge of the budget and company communications across the board. I ended up leading the implementation at the other three distribution centers as well.

The new system brought a lot of benefits including the possibility of interacting via B2B with core customers. It did require further training and additional work with all of the counterparts, but it was 100% worth it. A year after we replaced UPS with FedEx due to the better interfacing features supported by their new platform.

TURNKEY ELECTROPLATING PROJECT (Lima, PER) – April 1998

Several products have been developed for the purpose of polishing silver that serve to remove sulfur from the metal without damaging or warping it. Because harsh polishing and buffing can permanently damage and devalue a piece of antique silver, valuable items are typically hand-polished to preserve the unique patinas of older pieces. Techniques such as wheel polishing, which are typically performed by professional jewelers or silver repair companies, are reserved for extreme tarnish or corrosion.

Based on these facts, we decided to develop and implement a Turnkey Electroplating Process, which it became quite useful, as we started coating the Sterling Silver products with a thin layer of 99.99% Silver. This layer provided extra protection against abrasion, wear resistance, and corrosion. The aesthetic qualities improvement was so good that we were able to attract old customers to have the "new look" applied to their antiques!



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