Resume

Sign in

Plant Manager

Location:
Elkhart, Indiana, United States
Salary:
Negotiable
Posted:
January 17, 2017

Contact this candidate

Thomas Hayward

***** ********* ***** ~ Elkhart, IN 46514

Home: (574) ***-**** Mobile (574) *** **** E-mail: acyb0s@r.postjobfree.com

Executive Career Profile

Accomplished Manufacturing Operations Professional keenly focused on supporting corporate management goals and objectives while driving growth and profitability. Well documented proficiency in the [Automotive (Metal or Plastics), Wood Products, Recreational Vehicle, Industries]. Performance-evaluated as “exemplary” at propelling quality programs and initiatives. Recognized by peers and executives alike for a unique ability to gain maximum results with limited resources. Particularly adept at effectively identifying opportunities and establishing guidelines thereby providing tactical business solutions resulting in company wins. A resolute leader known for building strategic alliances, assuring cohesiveness, fostering trust and inspiring confidence at all levels.

Leadership

Attract Talent

Lean, Six Sigma, Kaizen

Operational Streamlining

Plant Consolidation

CORE Competencies

Initiative

Drive

Adaptability

Plant Turnarounds

Create Positive Climate

Foster Teamwork

Process Re-engineering

Profit Building

Value Analysis/Engineering

Functional Expertise /Accomplishments

Boosted performance from 67% to 92% On Time Delivery in a three day lead-time environment

Project-managed a $1.5M build-out adding 39,300 sq. ft. to existing premises and in-sourced 3 outside warehouses to enable the company to grow from $30M to $60M in sales at increased EBITDA.

Led rationalization of three distinct product line brands to run on one process and reduce SKU’s by 66% resulting in a skyrocketing of on-time delivery from 36% to 82%.

Championed the integration of hardware operations from 2 plants into 1 saving $700K per annum.

Steered the merger of hardware assembly lines in less than 60 days yielding an operating cost avoidance of $450K monthly with no customer issues.

Professional Experience

The Colson Group – St. Joseph, MI 2014 – 2016

$160M World’s largest Manufacturer of Casters and Wheels for Office Furniture, Medical, Automotive, Shopping Cart and OEM Industrial equipment markets employing 400 people globally.

Plant Manager

Selected to drive operational performance and profit improvement of a successful rapidly growing division with 100 employees – with up to 11 direct reports – with up to $50 million in annual sales.

Drove implementation of State of The Art Epicor ERP system at St. Joseph manufacturing plant in six months through team building and project leadership. (normal implementation time is 18 months).

On-shored three product lines from China reducing cost and lead time from 16 weeks to 3 days while improving the quality and appearance of the product.

Transferred the manufacturing of six product lines from Newnan GA plant as part of a plan to permit plant to be shut down and sold in six months.

Slashed Safety incidents from 4 Lost Time Injuries and 9 Recordable Injuries to one recordable in two years by implementing improved guarding, employee awareness, enhanced On Boarding Training, and enforcement of PPE discipline.

Chopped External Quality issues by 85% (30,000 ppm to less than 3,200 ppm) through improved process control, correction of tooling issues and focused hands on training on the production floor.

Processes included stamping, robotic and manual welding, CNC machining, CNC laser cutting, forming, tumbling, and assembly

Reason for leaving: Colson has been rapidly transforming eight caster companies into one. My position was eliminated and I was downsized with severance.

Thomas Hayward Page 2

Professional experience CONTINUED

Boyd Corporation – Elkhart, IN 2012 – 2014

$400M supplier of Plastic Extrusions, Rubber Extrusions and Converted products to the Recreational Vehicle, Automotive, Heavy Truck, Electronics and Aerospace markets employing 1600 people.

General Manager, Plastic Extrusion Division

Chosen to drive operational performance and profit improvement of a successful rapidly growing division with 100 employees – 10 direct reports – with up to $50 million in annual sales.

Leveraged production capacity on existing equipment through the use of Heijunka, level scheduling and SMED from producing $30 million in sales running 24/7 (4 shifts) and with heavy over time to producing $50 million in sales on 3 shifts 5 days per week with little overtime with the same number of employees, on the same equipment. (66% improvement in productivity)

Project-managed a $1.5M build-out adding 39,300 sq. ft. to existing premises and in-sourced 3 outside warehouses to enable the company to grow from $30M to $60M in sales at increased EBITDA.

Slashed Safety incidents from 4 Lost Time Injuries and 9 Recordable Injuries to zero incidents in two years by implementing improved guarding, enhanced On Boarding Training, and enforcement of PPE discipline.

Crushed FPY material scrap rate down from 17.1% to 5.7% through systematic correction of legacy tooling issues and enhanced operator and set up technician training.

Boosted performance from 67% to 92% On Time Delivery in a three day lead-time environment

Drastically Reduced External Quality issues by 75% (10,000 ppm to less than 2,200 ppm) through improved process control, and focused hands on training on the production floor.

Processes included plastic extrusion, blending, taping, assembly, and CNC machining and EDMing of tooling.

Reason for leaving: After successful completion of the turnaround and expansion projects above, I was downsized with severance.

TRUCK Accessories Group – Elkhart, IN 2010 – 2012

$160M supplier of fiberglass and aluminum truck caps, and specialty fiberglass components to the automotive OEM, aftermarket truck accessories and specialty vehicle markets with 800 employees.

General Manager, Midwest Operations

Directed the rearrangement of fiberglass cap plant from discrete operations to single piece flow, consolidated processes, and overhauled paint line process improving productivity by 20% and cut rework by 50%.

Chopped overhead by $700,000 per year through the consolidation of three plants into two by establishing balanced flow.

Aluminum cap labor reduced by 18% and throughput time cut by 75% by converting line from batch to one piece flow

Slashed labor on fiberglass truck hoods by 30%. Recordable Injuries for division reduced by 25%.

Reason for leaving: Due to the recession in the pick up and heavy truck markets, after the successful completion of the major projects above, my position was eliminated to reduce overhead, and I was downsized with severance.

ATWOOD MOBILE PRODUCTS – Elkhart, IN 2008 – 2010

$160M supplier of appliances, windows, doors and chassis hardware to recreational vehicle industry, seating hardware to RV, specialty vehicle, military, agricultural, and industrial commercial sectors with 1100 employees

General Manager, Hardware and Seating Division

Provided strong leadership and active participation in organizational advancement that resulted in division sales elevating by 12.5% in one year.

Orchestrated the insourcing of laser operations, leading to laser cutting costs decreasing by 35%.

Processes included stamping, brake press forming, roll forming, heat treating, powder coating, e-coating and assembly.

Reason for leaving: The new Vice President of Operations decided to bring in his own team from Dura Automotive and I was laid off with severance.

Thomas Hayward Page 3

Professional experience CONTINUED

HOMECREST CABINETS – Goshen, IN 2006 -2008

Manufacturer of residential wood kitchen and bath cabinetry that generates $160M in annual sales with 1100 employees

Vice President of Operations, General Manager

Reason for leaving: Due to the collapse in the housing market, MasterBrands our owner, decided to centralize and consolidate all of the top management roles into the headquarter in Jasper Indiana, I was downsized with severance with the rest of the top management team.

Fisher Hamilton LLC – Two Rivers, WI 2004 - 2006

Manufactures commercial and academic laboratory case work and furniture and generated $120 million in sales with 700 employees

Director of Wood Plant Operations (Union)

Reason for leaving: Fisher Scientific, our owners, were purchased by Thermo-Electron and the decision was made to close the plant. I was downsized with severance with 145 other people.

BAKER FURNITURE CO. – Holland MI 2000 - 2004

Baker Furniture manufactures and distributes premium residential furniture and generated $110M in sales with 1500 employees

Plant Manager

Reason for leaving: Our owners (The Kohler Company) decided to close this plant and move operations to Indonesia. I was downsized with severance.

BORG WARNER AUTOMOTIVE – Sallisaw, OK 1996 - 2000

High precision CNC machining of aluminum and cast iron castings and assembly and test of automotive engine oil pumps and engine air pumps. Process also included rotor balancing for electric air pumps.

Operations Manager

Launched a new to the world two stage engine oil pump to BMW on time, under budget and at zero defects.

Leverage Electric Air Pump production line using OEE, Level Scheduling, and Quick Change techniques to increase production from $5 million to $60 million in sales on same assets. ($20 million added profit).

Reason for leaving: I was recruited by Baker Furniture and promoted to be a Plant Manager

TETRA PAK, FLEXIBLE PACKAGING SYSTEMS – Lincolnshire, IL 1995 - 1996

Globally Sourced Food Packaging, Packaging Machines and Components

Sourcing Manager – Flexible Packaging Division

Reason for leaving: Our division relocated its headquarters from Lincolnshire, IL, to Berne, Switzerland and I was recruited back by Borg Warner Automotive.

BORG WARNER AUTOMOTIVE – Bellwood, IL 1989 - 1995

Stamping and forming of Automotive Friction Plates, Piston Plates Clutch Packs and One Way Clutch assemblies for Automotive Automatic Transmissions and Four Wheel Drive Transfer Cases.

Ford Friction Products Launch Team Leader (Engineering)

Launched 42 new Ford Friction Products (Concept to Production)

Reason for leaving: Was recruited by Tetra Pak and promoted to Global Sourcing Manager.

GENERAL MOTORS CORP., AC ROCHESTER DIVISION – Rochester, NY 1983 - 1989

Manufactures of Automotive Fuel Systems including aluminum and zinc die casting, CNC Machining and Screw Machining, Broaching, Heat Treating, Grinding, Polishing and Assembly of Steel and Stainless Steel Components.

Manufacturing Engineer, Quality Engineer

Reason for leaving: Left to marry my wife and to live in Chicago. GM didn’t have operations there.

Education

Northwestern University / Kellogg School of Management – Chicago, IL 1992

Masters of Management (MBA) in Finance and Marketing

University of Rochester – Rochester, NY 1983

Bachelor of Science in Mechanical Engineering

Villanova University – Certified Lean Six Sigma Black Belt – Villanova, PA 2010



Contact this candidate