STEPHEN PENNY

cell 435-***-****

aczr7i@r.postjobfree.com

Senior Operations Manager

Process Control Communication & Motivation Safety Education

An enthusiastic manufacturing professional with 17 years management experience in fiber, polymer & copper extrusion with 20 years total production experience. Great motivational skills include a keen ability to evaluate and place personnel in positions which maximize their productivity.

Lean strategies Six Sigma Team Leader

Outstanding safety record Successful cross training programs

Internal ISO auditor Excel in planning, preparation & execution of programs

CAREER HIGHLIGHTS

Established a strong safety program, set up an associate led system, with management support which emphasized proper techniques & strategies on a daily basis, attributing to 85% less injuries per year; allowing us to maintain a higher incidence of safety on a permanent basis throughout the facility. The plant received world-class rating under corporate directives during annual safety audit.

Implementation of Continuous Skills Development & Work/Operator Balance, developed a certification program & training packets, defining balanced workloads. Reduced manning by 16% over 11 months through balanced workloads, and by 23% ten months later. Decreased new operator training by two weeks; emphasis on cross-training strengthened team and process reliability increased 1.8%.

Reduced finished goods inventory, value stream mapping the process reduced lead time from 18 days to less than 5 days. Finished goods inventory reduced by 65%, freeing up valuable floor space for a 3rd & 4th production line.

Transformed a complex production planning program, by adapting JIT principles to three departments involved, into a large database using Excel. This improved a weak communication link within the plant and reduced customer complaints associated with mixed product to zero.

EMPLOYMENT

Senior Operations Manager, Milliken & Company, St. George, UT 435-***-**** 2007 - Present

Production Manager, Lab manager, Process Engineer Manager

Lead 5 managers, a production team of 33 associates in producing & testing fire retardant padding for the mattress industry to UL and ISO 9001 standards.

Setting annual budgets for departments; tracking/answering for KPI’s and P&L

Lead Six Sigma projects driving cost reduction. In a 5 month period established cost savings for over $1.1 million dollars for the year.

Developed a 3-5 year manning plan, using Lean principles to accomplish 2 of 3 phases in first 11 months for savings of $273K. Completing the final phase in the next 10, total annually savings of $453K; the final phase integrated maintenance technicians into production leadership and top machine operation.

Additional benefits of LEAN principles saw a reduction in product ticketing errors by 85%.

Established quality control measures in lab & production floor to achieve the use of the UL marking.

Production Manager, Cerro Flow Products, Cedar City, UT 435-***-**** 2005 - 2007

Lead a production team of 44 operators on a 4 stage drawing line and 3 finishing lines.

Created written safety training documents for hazardous work environment in the casting & milling areas

Established training documents with ISO formats.

Established NSF B88 standards, setting the facility’s quality apart from other copper tubing suppliers.

Instigated value stream maps to restructure shift schedule and process flow. Cross training improved material flow through weekend and graveyard shifts. Keeping a key machine running thru weekends without stopping prevented shutdown scrap. This reduced scrap by 35%, increased line capacity 11% and eliminated overtime.

Used Work/Operator Balance to redirect material handlers’ time to changeovers resulting in 50% reduction of changeover times.

Worked on a capitol expansion project to venture into HVAC tubing.

Production Supervisor, Nan Ya Plastics, Lake City, SC 843-***-**** 1999 - 2005

Supervised 3 – 8 man shifts.

ISO internal auditor and section coordinator.

Lead a cleaning & equipment installation crew around caustic sodas, high pressure/high temperature Ethylene Glycol & Polymer; trained with team on hazardous spills and evacuation drills.

Established a strong attitude towards safety. Using the principles of 5S, reorganized the training of individuals and the layout of the work stations.

Standardized ISO 9000 documents and developed them into training manuals. This aided in setting up a cross-training system that eliminated reliance on call-in and temporary labor.

EDUCATION

BS, Brigham Young University, Provo, UT - Mechanical Engineering 1998

AS, Ricks College, Rexburg, ID - Mechanical Engineering 1994

COMPUTER

Microsoft Office CHARTrunner Pro-E

SAP OneNote C++

TRAINING

CPR & First Responder Renewal Training, American Heart Association Annually

Train-the-Trainer Radiation & Laser, Liberty Mutual 2010

LEAN Principles, Harris LEAN 2008

Six Sigma, Milliken University 2007

ISO Internal Auditing, Pillar Management Associates 2005

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