Steve Lyles

M: 843-***-**** T: 843-***-****

Florence, SC 29501

Email: acxc91@r.postjobfree.com

http://webprofile.info/slyles/

ENGINEERING PROGRAM / CONTINUOUS IMPROVEMENT

Maintenance Business Transformation Lean Six Sigma

Engineering/Lean Six-Sigma practitioner who optimizes domestic and international operations through expertise in engineering, continuous improvements, quality, cost control, product development, and production management. Expert in providing the vision and leadership to drive organizational change and deliver sustainable bottom-line ROI. Repeated successes leading business units through startup, turnaround, and revitalization. Strategic partner and trusted consultant to senior management. Provide solid problem solving, decision making, and negotiating skills through proven expertise in:

Team Development / Deployment / Mentoring

Strategic / Tactical Planning & Execution

Implementation of Sustainability Measures

Plant Design / Startup / Maintenance

Process & Quality Improvement / Metrics

Resource Identification & Allocation

Capital & Operational Budget Planning

Research and Development

Opportunity Analysis / Solutions Development Johnson Controls Manufacturing Sys.

EXECUTIVE EXPERIENCE

Johnson Controls, Florence, SC 2013- Current

Global products supplier providing solutions to the automotive industry through its automotive experience and power solutions and service provider through its building efficiency group.

Power Solutions

Engineering/CI Manager

Directed and supported the operations by developing and managing team of engineers/maintenance and CI/Black Belt personnel in transforming plant from aftermarket provider to a Tier 1 supplier to 3 major auto manufacturers.

Average $1.0 million annually in productivity improvements utilizing CI team and tools (Lean, Six Sigma)

100 % completion of equipment selection, layout and installation of 2 new process lines for Tier 1 OEM’s

Ongoing management for deployment of Johnson Control Global Management System (JCMS) that includes nine principles with goal to reach world class in all within 4 years. Status – On-Track.

Established 2.5-year entire plant TPM program rollout. Currently on track. Attended global deployment immersion training and created deployment plan.

100 % Plant-Wide training conducted for JCMS, TPM, Standard Work, 5S programs, Environmental Awareness

100 % completion of capital projects. 15 projects in excess of $10 million

Averaged 18 % Year to Year improvement in KPI’s. Reported monthly to corporate management team

Certified ISO 14001 – Prepared documentation and managed audit. Trained in ISO 14001 audit process/projects auditing

TS 16949 (ISO for Automotive) – 100 % completion of Engineering/maintenance requirements. Certified with no findings.

ANPQP Training/ implementation for Nissan product management. 100 % Completion. Awarded business.

Conducted plant events in 5S, TPM, OEE, Value-Stream, SMED and Kaizen. YTY 28% improvement 5S.

Sonoco Products Company, Hartsville, SC 1977–2012

Multibillion-dollar global provider of consumer packaging, industrial products, protective packaging, and packaging supply chain services.

Sonoco Recycling

Engineering/Operation Excellence Manager (2009–2012)

Tasked with transforming business by utilizing engineering/maintenance, business systems, and operations to create Standard Work and drive continuous improvement of 40+ global recycling facilities collecting 3.5+ million tons annually from more than 15,000 major retailers, manufacturers, and municipalities.

$5-$9 million annual capital budgets optimized through analysis, prioritization, and forecasting of capital and operating requirements across division. Project Manager for 4 new plant startups.

97% consistency achieved in operations/metrics at 28 division-wide plants by creating Standard Work for Leaders and implementing divisional scorecard of KPIs.

$1.5 million annual increase (productivity) in scrap metal sales due to value-stream redesign. This included the processing, logistics and negotiation of new multi-year contract.

65%+ of business from major accounts protected through development of mobile apps running on tablets and cell phones that reduced transaction processing time from two weeks to instantaneous.

$127,000 avg savings produced after conducting 20+ Value Steams and Kaizens in-house and at customers.

0.36 Total Incident Rate attained for 28 plants in 12 months after implementing new Safety Council.

$500,000+ in initial productivity reached with additional $300,000 identified in equipment and hauling frequency by establishing OpEx, sustainability and recycling programs for 130 North American locations.

Conducted division-wide events in 5S, TPM, OEE, Ishikawa, SMED and Kaizens

Sonoco CorrFlex

Technical Sales Manager (2004–2008)

Directed and supported sales team of 11 providing Operational Excellence and Lean consulting to identify opportunities to improve packaging services processes for major consumer goods companies.

100% validation achieved of proposed supply chain and order fulfillment processes by developing discrete simulation models.

Identified 3 to 12% productivity and KPI issues with potential customers and their suppliers after conducting more than 40 Value Stream Assessments

Developed strategy to serve clients better by working with temp labor providers to manage the flexible scheduling of 100 to 1,200 temp employees.

60% reduction gained in development of promotional/display quotes on $175 million in sales from seven weeks to less than three using Lean and business process mapping.

Sonoco Packaging Services

Division Operating Excellence Manager (2002–2004)

Led staff of 68 across Engineering, Lean, Six-Sigma, and Maintenance delivering 3 to 13% in division performance and productivity improvements, collaborated with corporate team developing Operating Excellence for all 330 Sonoco plants, and identified training projects and potential candidates.

100% or greater productivity goals reached for each major consumer goods company outsourcing to Sonoco.

Developed Maintenance Center of Excellence across all plants that achieved 23% average improvement in OEE for Packaging Services locations and 2.7% average MRO expense reduction.

Awarded first OSHA VPP Star Certification two months ahead of target date by setting goal after receiving multiple awards/recognitions for safety.

Developed deployment of TPM, Six-Sigma and LEAN throughout the organization.

Sonoco Packaging Services

Division Business Systems Manager (1999–2002)

Assembled cross-functional team to process map and define requirements for business systems infrastructure to support international Packaging Services Division.

Captured Gillette as customer and positioned team for future growth in Europe by developing processes, integration strategy, and launching new operation in England in 11 days vs. 6+ months for initial operation.

Sonoco Packaging Services

Technical Manager (1997–1999)

Provided outsourcing, secondary, and promotional packaging for major consumer goods companies.

Spearheaded development of Packaging Services Division that grew from startup to $250 million in eight years.

15% improvement in inventory accuracy realized by developing and implementing new functionality to WMS that managed material flow to operations

Eliminated exposure to multiple issues by establishing domestic and international procurement procedure for capital equipment.

Served as project manager for 750,000 sq. ft. order fulfillment center that ships 1.7+ billion units annually. This created a new business for Sonoco Products.

Sonoco Corporate

Advanced Manufacturing Manager (1997–1998)

Managed select group of 7 engineers and scientists working on new products and processes company-wide.

Completed Six Sigma (Black, Green) and Lean training through Sonoco developed training teams.

14% improvement in quality related issues realized by developing SPC and data collection system with real-time interfaces to equipment for 23-plant division.

Granted patent for method to measure performance of paper cones that created competitive advantage by designing for specific product performance that changed manufacturing paradigm.

Additional Sonoco Position

Electrical/Project Engineer (1977–1997) - Over 40 new designs and multiple patents, records of invention.

EDUCATION

B.S., Electrical Engineering, University of South Carolina, Columbia, SC

PROFESSIONAL DEVELOPMENT

Six Sigma Black Belt, Hartsville, SC

Lean Methodologies, Hartsville, SC

Executive Leadership, Greensboro, NC

Computerized Maintenance Management, Greenville, SC

Microsoft Project, Virtual

Successfully Managing People, New York, NY

Warehouse Config & Mgmt, Farmingdale, NY

Sharepoint Application Development, Online

AFFILIATION

IEEE, Member

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