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Manager Engineering

Location:
Milwaukee, Wisconsin, United States
Salary:
130,000
Posted:
October 06, 2016

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DAVID J. GLADCZAK

New Berlin, Wisconsin • 414-***-**** • acwxvr@r.postjobfree.com www.linkedin.com/in/david-gladczak-31449842

ENGINEERING & MANUFACTURING MANAGEMENT

Experienced manager with more than 25 years of combined experience impacting corporate performance through skillful development, process engineering, project engineering, organizational improvements, and optimizations for plant, engineering, and manufacturing environments. Expertly align resources with enterprise objectives. Reputable for leading, coaching and mentoring lower level managers to exceed in their positions. Skillful team builder focused on the continuous delivery of process improvements and top quality products. Areas of expertise:

Process and Manufacturing Improvement Specialist R&D Process Control Planning Six Sigma Black Belt Quality Assurance Team Leadership & Mentoring Strategic Planning Results Driven Performance & Productivity Measurements “C” Level Relations Executive Presentations Communication Continuous Improvement

PROFESSIONAL EXPERIENCE

ALLIANCE PACKAGING GROUP, Saukville, Wisconsin 2015 – June 2016 (Plant Relocation) $15M contract manufacturer and packager of lip balm and OTC products.

Plant Operations and Site Engineering / Facilities Manager

Directed all manufacturing, engineering and maintenance operations and fully accountable for plant safety protocols, equipment maintenance & optimization, and warehousing operations. Hold $5K capital approval authority, problem solved facility and equipment issues, and prepare manufacturing operations for 20% growth over the next 3 years.

Optimized equipment performance which resulted in a 17% increase in production output across 6 filling/packaging lines.

Spearheaded R&D trials of mixing and filling processes and container design for new OTC product introduced to the German market for customer.

Implementation of lean manufacturing principals creating work cells that reduced manpower by 12% and increased packaging output by 100%.

Introduced equipment maintenance program and PM scheduling for plant equipment and facility mechanicals.

DAVID J. GLADCZAK Page 2 acwxvr@r.postjobfree.com

KLEEN TEST PRODUCTS, Port Washington, Wisconsin 2004 - 2015

$135M contract manufacturer and packager of wet wipes, dryer sheets, soft goods, liquids, disposables, OTC, and pharmaceutical products.

Plant and Site Engineering Manager

Directed 7 manager level reports, and a total of at times 200 total employees running 3 shifts 5-7 days/week. Overall accountability for safety, quality, customer service, production output of eleven manufacturing lines, and drive profitability. Hold $3K capital approval authority, problem-solve facility and equipment issues, and prepare plant and personnel for new product launches.

Operational Highlights:

Coordinated the installation, start-up, commissioning, validation and final de-commissioning of several customer and KTP owned multimillion dollar processing lines for the manufacturing of home care products for Procter & Gamble and Henkel.

Define and initiate projects, and assign Project Managers to manage cost, schedule, and performance of component projects, while working to ensure the ultimate success of plant performance.

Directed the process for implementation of a TPM program for processing equipment while Plant and Facilities Manager at multiple plants.

Achieving 75% uptime efficiency and 4 sigma quality results for 2 plants within 6 months of starting operations at Kleen Test.

Maintained 0 OSHA reportable injury levels for the year at 2 plants by introducing DuPont STOP safety program at plant level at Kleen Test.

Engineered equipment improvements allowing a SMED reduction by 50% across multiple production lines in several plants.

Awarded Pinnacle Quality Award for 100% audit score of quality assurance program from Proctor & Gamble, 1st contract manufacturer for P&G Home Care Division to receive award.

SELLARS, WIPERS, & SORBENTS, Milwaukee, Wisconsin 2002-2004

$36M privately-owned industry leader as fully integrated manufacturer of industrial spill sorbents and wiper products.

Operations/Plant and Site Engineering Manager

Spearheaded overall direction, production, and profitability of a Double Recrape Process (DRP) plant, 1 of 7 worldwide that can manufacture this product. Supervised 28 direct reports over 2 manufacturing lines running 3 shifts 5 days/week. Determined plan production schedules, troubleshot production, maintenance and quality issues.

Operational Highlights:

Managed the schedule for final assembly, installation and validation of a $10MM proprietary DRC machine upon joining the company in the role as Operations Director.

Streamlined manufacturing processes resulting in 5% waste reduction ($25K monthly savings) within 1st 6-month period of equipment operation.

Increased 0 defect (defect-free) manufacturing material from 85% to 99%, equivalent to $3M annual cost savings, by introducing “High Performance Work Team Strategies”.

Improved production efficiencies to 80% within 1st 7 months of operation, resulting in achievement of manufacturing levels of over 1.75M pounds per month 6 months earlier than anticipated, by implementing Focused Factory, RCA, and Lean Manufacturing Techniques.

DAVID J. GLADCZAK Page 3 acwxvr@r.postjobfree.com

PPG INDUSTRIES, Oak Creek, Wisconsin 1990-2000

An $8 billion Pittsburgh based global ISO 9000 manufacturer of coatings and resins, fiberglass, glass and chemicals.

Manager, Industrial Filling Operations (1999-2000)

Directed manufacturing operations producing 14B gallons of product annually. Reduced cycle time 50% by designing & building proto-type filling equipment, increased productivity 43% by implementing specialized techniques, and increased product volume 1.2M gallons by developing and utilizing process changes. Earned 2 corporate commendations.

Manager, Industrial Engineering & Processing (1993-1999)

Spearheaded engineering & manufacturing processing functions with $1.5M annual capital budget and held $10K capital approval authority. Eliminated $100K in reproduction costs by redesigning equipment cleaning process, achieved 85% decrease in defective 1st-run products by optimizing processes and reached 99.5% defect-free manufacturing, and saved $1.5M in sub-standard product losses (SSPL) by implementing TQM practices.

Career Note: Served as Sr. Development Engineer I and II (1990-1993).

EDUCATION

Bachelor of Science in Chemical Engineering

University of Wisconsin, Milwaukee, Wisconsin

ADDITIONAL PROFESSIONAL TRAINING

Six Sigma Black Belt Certification Six Sigma Green Belt Certification DuPont Safety Program

Leading High Performance Work Teams & Teamwork Lean Manufacturing Business Training & Financial Management Material/Capacity Requirements Manufacturing Planning & Control Systems

Just In Time Inventory Management Leading For Performance Improvement Mechanical Engineering & Engineering Design

DESIGN ENGINEERING CORPORATION, New Berlin, Wisconsin 1995-Present

Principal

Founded company, serve as principal consultant, and specialize in capital project installations and process engineering improvements, as well as integrating Six Sigma Lean Manufacturing, Kaizen, and Synchronous Manufacturing techniques.

Reduced GE Medical Systems overhead costs $250K by collaborating on a Six Sigma project with black belts to improve Chinese-manufactured CT equipment quality.

Developed long-term Ergonomic Plan and implementation strategy for Brady Corporation’s Coated Products Division Converting Department.

Designed CIP production equipment and a manufacturing cell design for Hentzen Coating’s proprietary manufacturing process.

Financial Reporting

Accomplished 11 continuous improvement projects resulting in $150K of cost savings.



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