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Lean Manufacturing Customer Service

Satellite Beach, Florida, United States
October 03, 2016

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ROBERT S. PRUSS *** Hibiscus Drive, Satellite Beach, FL 32937 321-***-****


Operations/Manufacturing professional with demonstrated successful experience driving lean innovations and delivering results for start-up and high-growth operations. Pioneer in Toyota Production System (TPS), 5S, Kanban, Lean Manufacturing, Six Sigma, and Kaizen implementation. P&L responsibility with both short and long range planning. Proven record of increasing profitability, improving efficiencies, and improved customer service. Extensive production management experience in implementing Process Metrics and deployment of Lean Manufacturing initiatives. Coordinated the transfer of micro machining technology from Asia.


P&L Responsibility Six Sigma – Green Belt Certified Customer Relations

Driving Cultural Change Hands-on Manufacturing Leader Strategic Planning

Team Building Plant/Process Start-Ups Safety Programs

Facility Management 5S Events Project Management


2011 - 2014

SealMaster of Atlanta / Georgia Pavement Products

Atlanta, Georgia

Plant Manager

Overall responsibility for daily and long term plant operations.

Implemented company-wide safety program. Trained employees per OSHA standards for confined space entry, lock out/tag out and forklift operator safety.

Established a raw material and finished goods inventory control system transforming from a push system to a Kanban pull system resulting in an annual savings of 35%.

Reduced scrap and waste by 30% through Lean Manufacturing initiatives.

Initiated in-house QA lab to test sealer in process and provide real time quality data for process control.

Coordinated the start-up of five distribution centers.

2009 - 2011

Independent Contractor

Conducted on-site plant audits and proposed improvements to enhance the overall production efficiency through the application of key Lean Manufacturing practices: 5S, Value Stream Mapping (VSM), Cycle Time Reduction, TPM, OEE, and Kaizen.

Performed facility safety audits implementing safety initiatives that resulted in reducing OSHA recordables by 50% and worker’s compensation claims by 25%.

Established a company-wide standardization of process equipment for spare parts which resulted in improved efficiencies and reduction in inventory.

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2006 – 2009

OFS Fitel (Furukawa Electric, Japan)

Carrollton, Georgia

Plant Manager/Operations Manager

Provided leadership to a team of first-line managers dedicated to the positive performance of the operation.

Managed Process Engineering Department consisting of a team of engineers responsible for maintaining and improving the process in all areas of manufacturing.

Developed annual budgets and long term strategic planning for operations.

Directed installation of capital equipment to ensure systems were installed and functioning according to required implementation schedule and specifications.

Utilized value stream mapping to identify and eliminate waste, as well as evaluated potential changes in work flow to maximize production efficiencies.

Improved overall production efficiency through the application of key Lean Manufacturing practices: 5S, Cycle Time Reduction, TPM, OEE, and Kaizen.

Implemented and monitored Metrics to achieve overall manufacturing excellence.

Implemented a daily procedure to insure the OTD metric consistently met or exceeded the corporate goal.

2003 – Present Florida Licensed Realtor

1985 – 2002

NSG America, Inc. (Fiber Optics Division of Nippon Sheet Glass, Ltd., Japan)

Somerset, New Jersey

Plant Manager

Coordinated the facility and production start-up from inception to multi-shift operational stages.

Trained in the concepts of the Toyota Production System (TPS).

Implemented Lean methods: 5-S, Pull Systems, SMED (single minute exchange of dies), Poke-Yoke, 5 Why’s, TPM, and Kaizen Leadership.

Designed plant layout to accommodate a Lean Manufacturing Environment.

Coordinated the transfer of manufacturing processes from U.S. to Asian facilities.

Oversaw planning/scheduling of production requirements with U.S./Asian facilities.

Established corporate strategic plan and objectives to insure overall financial stability of the company.

Responsible for preparing and maintaining annual budgets.

Maintained continuous process improvement with established supplier partnerships that improved manufacturing processes and reduced costs.

Coordinated with quality control the ISO 9002 documentation and adherence to ISO standards.

Responsible for introducing various cost savings initiatives throughout the production process.

Responsible for several building expansions with the largest expansion being $5.7 million building and

$4.3 million for equipment transferred from Asia.


Six Sigma Black Belt

Toyota Production System (TPS)

Dupont’s STOP Safety Training Program

CERTIFICATIONS Six Sigma Certified Green Belt

Institute of Industrial Engineers – Atlanta, GA


Glassboro State College, Glassboro, NJ

Bachelor’s Degree

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