Robert Saurer

Simpsonville, SC *****

Cell: 205-***-****

ad0v7v@r.postjobfree.com

Education

Rochester Institute of Technology - Production Management/Industrial Engineering

Dual program in BSIE and MS in Statistics

Stark State College - AAS Business Management

Employment History:

MMI Wood Works

4/2022 to 7/2023

Title,: Consultant for EHS & Lean Manufacturing

●Implement New Plant EHS policies

●Implement Lean Manufacturing: document all SOP's

●Develope product flow through the plant

●Take the waste out of the products

●Develope New Business Plan

SPV Corporation, Enoree, SC 05/28/2019 to 04/13/2020

Title: Plant Manager

●Processing operation of vermiculite through a fully integrated network of 15 mines and 12 refining, processing and packaging facilities.

●Establishes and maintains mill operations in accordance with all regulatory agencies from the county, state and federal regulations.

●Develops new or improved processes to lower costs and provide more effective and efficient operations.

●Investigates, recommends and oversees capital expenditure projects.

●Establish recertification in ISO-9000 and 9001.

●Establishes work plans and goals and implements processes to achieve the timely realization of those goals.

●Improved plant through-put from 52% to 91% using Lean Manufacturing and six sigma.

●Full P&L responsibilities with sales of $19MM/year

●Reason for leaving: job eliminate due to Ownership is reorganizing the Americans and closing plants.

●Retired

Exide Technologies, Muncie, IN 2/2012 to 5/2019

Title: Plant Manager

●Manufactures lead ingots, 1200 pound blocks, plastic battery casings, 3 tons lead strips and sulfur acid for lead acid batteries. Processed 400,000 gallons/day of waste water using filtration, sand and polymers.

●Cross train production staff members to lead and evaluate other departments. The staff member is on a 6 month rotation in to manage the respected department and supervisors.

●Directs, manages, and coordinates overall recycling plant operations, and Strip Mill including production, quality, engineering, maintenance, shipping/receiving, financial and human resources.

●Develops and maintains a highly motivated plant organization capable of achieving the Division's goals and objectives for the North American Recycling Group.

●Trained OSHA HAZWOPER Incident Commander for any hazardous waste operations and emergency in accordance to CFR 1910.120.

●Develop, initiate control practices and procedures, recommend and implement modifications to equipment and processes.

Accomplishments:

●Improved production OEE, scrap and quality by implementing Lean Manufacturing with a 2014-2019 EBIT of 32.8%.

●Improved production using TPS Workshop and Kaizen Events; improved manufacturing output from 76% to 91% (89,000 lead tons/year to 115,000 lead tons/ year) and through put from 79% to 94%.

●Improved Strip Mill production from 55 tons/shift to 82 tons/shift with a 94% OEE.

●Improved billet production from 121”/min. to 143”/min.

●Scheduled 15 refinery vessels to improve up time from 68% to 93% using metallurgical batches based on last metals used in the vessels.

●Prepare production cost and statistical reports as required and recommend action plans for improvements to manufacturing operations.

●Operating Material Budget of $32MM/yr and Capital Projects up to $15MM.

●Proficiency with Excel, Word, Power Point and SAP. We institute ISO 9000 Quality Programs, 6 Sigma, TQM, Lean Manufacturing, and Kaizen Events

●Union negotiating and grievance experience

Reason for leaving: The Company has closed 4 plants in 7 months and in chapter 11. Looking for a better opportunity.

Harsco Minerals, Ghent, KY 10/2010 to 5/2011

Title: Site/Plant Manager

●Cross train production staff members to lead and evaluate other departments. The staff member is on a 6 month rotation in to manage the respected department and supervisors.

●Plan, direct and coordinate the operations of Metal Recovery plant managing operations of hot slag handling for customers.

●Formulating policies, managing daily operations and planning the use of raw materials and human resources.

●Responsible for managing and implementing ISO/QA programs.

●Responsible for managing and implementing safety programs and necessary employee training assure a safe work place.

Accomplishments:

●Zero recordable and lost time accidents in 2011 vs. 19 recordable and 3 lost time accidents in 2010

●Increased plant efficiencies from 62% to 94%, Zero turnover rate in 2011 vs. 27 in 2010

●Zero OSHA citations vs., 3 in 2010, plant became profitable in March 2011 of $180K vs. a deficit of $625K in 2010.

Reason for leaving: My position was eliminated due to a merger.

US Pipe & Foundry, Bessemer, AL 9/2006 to 10/2010

Title: Melting/Casting Manager

●Manufactures ductile iron pipe from 4” dia. to 64” dia. all 20’ long. Processed 1.4MM gallons/day of waste water using filtration, sand and polymers in our Waste Water Treatment Plant.

●Cross train production staff members to lead and evaluate other departments. The staff member is on a 6 month rotation in to manage the respected department and supervisors.

●Manage 2-130”, 120 ton/hr equaling 2,160 tons/day iron and ductile iron Melting Cupolas with 6 Melting Supervisors, 4 metallurgists and a 4-CI Engineer in a 18 hour melting operation.

●Manage 6 horizontal Casting Machines from 12” to 64” diameter pipe operation utilizing 5 Casting Supervisors, Casting Specialist and 3 CI Engineers in a 2-shift operation with sales of $550MM.

●Prepare production cost and statistical reports as required and recommend action plan s for improvements to manufacturing operations.

●Develop, initiate control practices and procedures, recommend and implement modifications to equipment and processes.

●Operating Material Budget of $46.7MM/yr

●Proficiency with Excel, Word, Power Point and SAP.

Accomplishments:

●Improved production OEE, scrap and quality by implementing Lean Manufacturing with a 2007, 2008 and 2009 EBIT of 17.5% to 20%.

●Improved production 57.7%, reduced scrap 62.1% and shipped product 48 hours after an order was placed vs. 15 days.

●Helped establish ISO 9000 Quality Programs, 6 Sigma, TQM, Lean Manufacturing, and Kaizen Events. Also dealt with union negotiations.

Reason for leaving: company was losing $6MM to $8MM/month, closed 3 manufacturing plants and was up for sale.

Babcock and Wilcox (Foundry), Barberton, OH 11/02 to 9/06

Title: Operations Manager/ISO-9000 Coordinator

●Manufactures castings from 500 pounds to 30 tons.

●Cross train production staff members to lead and evaluate other departments. The staff member is on a 6 month rotation in to manage the respected department and supervisors.

●Improved production OEE, scrap and quality by implementing Lean Manufacturing with a 2003, 2004 and 2005 EBIT of 20 to 27%.

●Manage 2-150 ton electric arc furnaces with 4 melt supervisors and 3 metallurgists producing iron and ductile iron casting.

●Supervised a management team consisting of a Superintendent, 5 Supervisors and a CI Engineer with sales of $10.5MM.

●Responsible for P&L, HR, Purchasing and Quality.

●Poured billets castings from 10 tons to 25 tons used in the manufacturing of ship making parts.

●Conduct union business to include grievances through the 3rd step and negotiate union contract etc.

Reason for leaving: company was out sourcing work to China

LeBaron Foundry Inc., Brockton, MA 8/00 to 7/02

Title: Plant Operations Manager (230 employees)

●Manufactures castings from 200 pounds to 50 tons.

●Cross train production staff members to lead and evaluate other departments. The staff member is on a 6 month rotation in to manage the respected department and supervisors.

●Manage a 60”, 20 ton/hr iron and ductile iron, Melting Cupola with 5 Melting Supervisors and 2 metallurgists.

●Managed all the manufacturing operations utilizing a team of 2 Superintendents and 9 Supervisors in a 2-shift operation with sales of $18.2MM.

●Directly responsible for support groups including Sales, Accounting, HR, Engineering, Purchasing and Quality.

●Develop, initiate control practices and procedures, recommend and implement modifications to equipment and processes

●Conduct union business to include grievances through 3rd step.

Accomplishments:

●Improved production 47.7%, reduced scrap 51.3% and shipped product 72 hours after an order was placed vs. 21 days.

●Instituted the ISO 9000 quality program

Reason for leaving: plant closed

Empire Steel Casting, Reading PA 10/98 to 8/00

Title: Operations Manager

●Manufactures 200 pound to 25 ton castings. Processed 2mm gallons/day of waste water using filtration, sand and polymers.

●Cross train production staff members to lead and evaluate other departments. The staff member is on a 6 month rotation in to manage the respected department and supervisors.

●Manage 2-200 ton electric arc furnaces with 5 melt supervisors and 2 metallurgists producing iron and ductile iron casting.

●Manage the day to day operations utilizing 3 Superintendents and 15 Supervisors with sales of $16.2MM.

●Directly responsible for P&L, existing Customer Accounts, HR, Engineering, Quality and Purchasing.

●Poured billets castings from 30 tons to 50 tons used in the manufacturing of aerospace and government parts.

●Conduct union business to include grievances through the 3rd step and negotiate union contract etc.

Accomplishments:

●Scheduled 20 refinery ladles to improve up time from 58% to 91% using metallurgical batches based on last metals used in the vessels.

Reason for leaving: plant closed

Aluminum Alloys Inc., Sinking Springs, PA 6/95 to 10/98

Promoted: Production Manager

●Manufactures 20 pound to 5 ton castings.

●Cross train production staff members to lead and evaluate other departments. The staff member is on a 6 month rotation in to manage the respected department and supervisors.

●Manage all production utilizing 2 Superintendents and 5 Supervisors in a 2-shift operation with sales of $25.1MM.

●Develop, initiate control practices and procedures, recommend and implement modifications to equipment and processes.

●Poured 18 different aluminum alloys used in electrical industry, pharmaceutical, automotive and defense industry.

Accomplishments:

●Scheduled 20 refinery ladles to improve up time from 75% to 90% using metallurgical batches based on last metals used in the vessels.

Hired: Quality Assurance Manager

●Manage all Quality Assurance functions utilizing 2 Quality Assurance Supervisors and 16 hourly employees in the foundry and machining operations.

●Directly responsible for communicating and resolving quality issues with the customer, as well as updating and revising blueprints and cost evaluations.

Accomplishments:

●Responsible for 80% completion of our ISO 9000 program. Updated QA Manual and documentation of processes/procedures.

●I was certified as a Level III X-Ray Reader and Inspector for nuclear parts.

Reason for leaving: No growth opportunities

Michigan Wheel Corp., Grand Rapids, MI 6/92 to 6/95

Plant/Foundry Manager

●Manufactures 200 pound to 15 ton castings .

●Cross train production staff members to lead and evaluate other departments. The staff member is on a 6 month rotation in to manage the respected department and supervisors.

●Managed all manufacturing operations utilizing 1 Superintendent and 6 Supervisors with sales of $21.9MM.

●Responsible for P&L, Budgets, Engineering Services, HR and Purchasing. Develop, initiate control practices and procedures, recommend and implement modifications to equipment and processes to improve operating efficiencies.

●Prepare production cost and statistical reports as required and recommend action plans for improvements to manufacturing operations.

●Conduct union business to include grievances through the 3rd step and negotiate union contract etc.

Reason for leaving: plant closed

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