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Manager Plant

Morganton, North Carolina, 28655, United States
January 21, 2017

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Roy Heeralall

Morganton, NC ***** 828-***-****

Senior Manufacturing Operations Manager

Optimize operational performance through relentless pursuit of continuous improvement and coaching cross-functional teams.

Develop collaborative leadership teams focused on improving key performance indicators, leading integration projects and cost reduction initiatives and transforming plant environments. Demonstrate expertise in all core aspects of plant management, including safety, continuous improvement, finance, quality systems, operation processes, engineering, materials management and logistics in the automotive industry. Optimize productivity to gain profitability while following Lean-Sigma Methodology and favor team empowerment.

Adept at creating a performance culture through process execution and talent development. Intuitively analytical leader known for personal credibility, integrity and effective communication.

Expertise includes:

Strategic Planning

P&L Management and Budgeting

Operation Excellence and Metrics

Program Management

Business Process Improvement


TS 16949 ISO 9001 ISO 14001

Leadership Development

Supply Chain and Logistics


Professional Experience

LYDALL Inc., Hamptonville, NC 2016 to present

Plant Manager

Led $80M P&L Business Unit, including operations, quality assurance, engineering, maintenance, supply chain and logistics, supporting strategic accounts comprising Ford, GM, Nissan, BMW, and Mercedes.

Spunfab Adhesive Fabric, Cuyahoga Falls, OH 2015 to 2016

Sales and Operation Manager

Led manufacturing team and manage South/east sales terrority.

JANESVILLE ACOUSTICS, Division of Jason Industries, Inc. (JASN) Jason 1999 to 2015

$300M Tier 1 and Tier 2 provider of automotive acoustical assembled component and die-cuts to most major automotive OEM’s.

Plant Manager, Richmond, IN 2014 to 2015

Built Greenfield site, in under 9 months to produce underbody insulators for new Chrysler Minivan, comprising 1 fiber line and 3 modular molding cells that required tool changes every shift. Incorporated Lean principles, including SMED along with Safety, Quality and 5S into every step of process. Achieved goal of total annual sales of $22M with an expected Earnings Before Interest, Taxes, Depreciation and Amortization (EBITDA) of $6.6M.

Managed all aspects of daily operation, including building and equipment installation, ensuring, aggressive timelines were met and closely monitored by Fiat-Chrysler.

Executed start-up plant on time, within budget and as World Class Manufacturing facility through monitoring daily progress base on detailed Action Item Sheets and participating in hiring process to ensure cohesive team with adequate skill sets.

Plant Manager, Old Fort, NC 2011 to 2015

Established Richmond Plant while overseeing Old Fort Plant. Led $50M P&L Business Unit, including operations, quality assurance, finance, supply chain and logistics, supporting strategic accounts comprising Chrysler, Nissan, Toyota, BMW, GM and Mercedes. Plant consisted of 3 fiber lines to support outside customers and 14 modular internal cells, producing specialized assembled components for various automotive platforms.

Managed and directed non-union staff of 20 salaried and over 220 hourly employees, achieving consistent monthly results using all aspects of Lean Production Systems.

Awarded coveted 2014 General Motors Supplier Quality Excellence Award and captured new business through using Visual Standard Operations in all processes to ensure high quality throughout every step of process.

Achieved over 25% EBITDA for 3-consecutive years by maintaining Lean principles previously implemented.

Attained 10% annual EBITDA improvement, using advance Lean Manufacturing Principles, including and Six Sigma techniques, including Process Failure Mode, Effect Analysis (PFMEA) and Root Cause Analysis.

Achieved over 1M hours without no employee absences through proper 5S and Visual management as well as building rapport and increasing morale, including treating all employees with respect and frequent communication from different levels of management. -

Operation Manager, Old Fort, NC 2007 to 2011

Improvement Manager, Norwalk, OH 2004 to 2007

Worked under guidance of TBM Consulting, driving Lean-Sigma Methodology principles in 9 manufacturing plants. Managed implementation of Toyota Production Systems in all plants, including Value Stream Mapping (VSM), quality, cost, delivery, increased OEE and safety.

oImproved Quality to over 99% and reduced overall costs 25%, using Lean-Sigma Methodology and employee participation.

oAchieved 100% On-Time delivery to customer, using JIT principles.

oIncreased OEE by implementing TPM approach to promote autonomous maintenance, reducing downtime and SMED techniques.

Division Process Engineer, Norwalk, OH 1999 to 2004

Assisted establishing Greenfield manufacturing site in Newcomerstown, OH. Ensured Environmental Compliance in 9 manufacturing sites.

Documented and streamlined processes in 9 manufacturing sites, increasing production output, including safety awareness.



Manufacturer of custom made limousines and funeral hearses. - Process Engineer - Materials Manager


Bachelor of Science (BS) Business Management, Gardener-Webb University, Boiling Springs NC, Anticipated Graduation, July, 2018

Associate is Applied Science – Business Administration, Western Piedmond Community College, Morganton, NC, Anticipated Graduation, July, 2017

Bachelor of Science (BS), Mechanical Engineering, University of Guyana/London, Guyana, South Africa


Shop Floor Kaizen Breakthrough Instructor Training, Certified Lean-Sigma Trainer, Six Sigma Green Belt Certification.

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