Plant Manager Supply Chain

DAVID SMITH

*** ****** **. • San Marcos TX *****

512-***-**** • **********@******.***

PROFESSIONAL SUMMARY:

20+ yrs. of experience being a service-oriented Project / Operations / Plant Manager with high profile international and U.S. automotive manufacturing and CGMP experience.

Demonstrated expertise leading multi-site manufacturing and distribution operations, with a track record of implementing continuous improvement through Lean and Six Sigma manufacturing principles.

Proven team leadership experience maintaining facility production, improving manufacturing processes, and streamlining operations to increase output and profitability.

Skilled at negotiations, strategic supply chain planning, and product and portfolio management.

Solid experience designing business turn-around strategies and improving organizational performance.

Establishing annual operating plans, removing cost, and creating a work atmosphere that is engaging, creative and encourages a team environment.

SKILLS:

Management Experience

Inventory Control ERP/MRP IQMS, SAP,

JD Edwards

Lean Manufacturing

Automotive TS16949

Mechanical Engineering

Metal turning

Process Engineering

Employee Engagement

Clean room Class 100-10,000

Capital Budgeting

Training / Development

Manufacturing Engineering

Performance Management

Supply Chain Performance

Logistics

Business Development

Customer Focus

Strategic Direction

Continuous Improvement

Injection Molding

Accountability

Metal Manufacturing

PROFESSIONAL TRAINING:

Advanced Leadership Development Program

Six Sigma Green Belt

Extended Sourcing Operations Training. Winner Diamond Manufacturing Award for 3M 2 times

EDUCATION:

Southwest Missouri State, Bachelor of Science in Biology / Chemistry, Springfield, Missouri

PROFESSIONAL EXPERIENCE:

Alleguard, Monticello Arkansas (Contract) 04-2024 to Present

Hired to turn around an ESP foam manufacturing facility in Monticello Arkansas

Started and ran a safety program/ team across 2 shifts

Leaned out shape molding department implemented 100% 5S increased through put increased 18%

Leaned out shape routing operation removed 3 people increased though put 119%

Board Feet per labour hour went from 321 to 711

Cost per board foot went from $0.42 to $.023

OTIF went from 63% to 95%

National Composites LLC, Joplin MO

Director of Operations Able Manufacturing Nov 2022- Jan 2024

(Multi-Site)

Hired into failed 350,000 SFT composites facility to make the business profitable, 2022 lost $3.5MM

Split the P&L and created a separate business unit for the metal cab manufacturing business $10MM 24% OP.

Established a safety team that received 1st responder training. Implemented daily safety walks for each area.

Recordables went from 11 in 2022 to 3 in 2023.

Daily production went from $62,000 in 2022 to $112,000 in 2023.

OTIF went from 36% to 92%.

Full P&L responsibility, present quarterly financials to owners and investors.

Plastikon Texas LLC, Kyle TX Dec 2021- Nov 2022

Project Manager Contract position (Injection Molding & Compression Molding)

Responsible to start a green field facility to be turned over upon completion.

Enabling the transition to Production Support, SAP Master Data / transactional data dependencies and Project scheduling through MS Excel.

Manufacturing Operations Management (Dispatching Production, Detailed Production, Scheduling, and Reliability assurance) – Workflow / recipe control, operational process steps to accomplish procedure.

Business Planning & Logistics (Plant Production Scheduling, Operational Management) – Establishing basic plant schedule, production, material use, delivery and shipping and determining inventory levels.

New Plant start up to service the automotive industry in Austin Texas

Equipment install and building preparation.

4 Injection molding machines 750 Ton to 4000-ton, compression molding and water jet cell

2 sonic welding and robotic cells along with assembly line.

Qualified all components and finished goods to meet the demanding timeline of our customer.

Met start up time and production schedule.

Received financial package up completion.

48forty Solutions, LLC, Springfield, MO Apr 2021 – Nov 2021

Plant Manager

Hired to turn around a pallet manufacturing location in Springfield Missouri

Revenue went from $30K per week to $130K per week.

Clean facility and implemented 5 S.

Constructed process map for material flow analysis and laid out production floor.

Production went from 700 pallets per day to 2200.

Turn over went from 300% to 5%

Royal Oak, West Plains, MO Mar 2019 – Mar 2021

Plant Manager

Hired into an aging facility and company to improve all metrics of manufacturing.

Provide cross-functional expertise, compliance, and SAP Master Data knowledge to internal stakeholders.

Established a reporting structure and a continuous improvement program.

Reduced TRIR from 9.5 to 2.5, daily safety topics at shift meetings and moved from CBS to BBS

Reduced charcoal by $7.25 per ton over 60,000 tons, Reduced lighter fluid by $.30 per case over 3.6MM cases.

Developed a 5S presentation, trained and implemented 5S throughout the 600k Sq. Ft. facility.

Responsible for hiring, evaluations and full P&L

FLOWBELOW, Austin, TX Sep 2017 – Nov 2018

Plant Manager (Company sold and moved) (injection molding, assembly)

Planning, Manufacturing, Cost Accounting, Quality Assurance and Supply Chain.

Established performance metrics to measure inefficient operations and implemented lean practices.

Improved throughput 33% and reduced overtime 70% (Process Improvements)

Improved on-time customer deliveries from 60% to 94% within 3 months, exceeding customer requirements.

Established inventory management techniques in warehousing area to track turns, and inventory accuracy.

Worked directs with Business Management and finance to establish operation budget to identify business metrics and direction and objectives for the year and implemented cost control measures to identify key capital expenditure, and where to cut expenses.

SCHWEITZER-MAUDUIT INTERNATIONAL, INC, Austin, TX Jan 2015 – Jul 2017

Plant Manager (Company merged factory closed building) (injection molding, extrusion)

Lead turn around for a plant that was -$1.1MM in loss, with 16-week lead time 60% on time in full to customer with a scrap rate of 43% and quality complaints totalling $560,000 in 2015. Responsible for daily involvement of all operations and managing a team of 12 managers, while maintaining environmental compliance with city and state.

Achievements:

Established metrics to measure efficiency of current operation and establish credible base line data.

Streamlined facility production lead time from 14 weeks to four weeks within four months by introduction lean initiatives increasing productivity, introducing SMED through a Kaizen event.

Implemented S&OP that level loaded scheduling and maximized run times, streamlining product manufacturing, moving toward operational excellence.

Improved on-time customer deliveries from 60% to 99% within five months.

Lowered production scrap from 38% to 15% delivering saving $1.3 million annually.

Worked with Quality Management to perform root cause analysis to develop corrective actions and quality training to reduce product returns from $560,000 to $21,000 within 1 year.

Implemented internal NCR process (updated quality standards) oversaw installation of the Visual Quality System to ensure quality assurance and coach team members on new methodology, to ensure customer specification are met.

Worked with Employee Health & Safety manager and created safety counsel, updated appropriate safety procedures, and create a safety culture; didn’t receive any OSHA recordable in 2016 or 2017.

FLAMBEAU INC, Phoenix, AZ Apr 2013 – Nov 2014

Plant Manager (injection molding, assembly, automotive and clean room, medical device)

Multi-Site

Injection and blow molded thermoplastic components, medical device, automotive and healthcare products 13485 Certified and contract manufacturing of assemblies worldwide. $38MM, 165 employees 3 sites

Worked with controller to develop departmental operating budget and create vision for the plants.

Implemented lean tools to reduce waste and employee development, saving $1.6 million in manufacturing cost.

Project Management: Completed medical molding 13485 (medical device) clean room facility and earned certification.

Project Management Skills: Lead construction from ground up, a blow molding facility on Phoenix campus, working with city regulatory administration to ensure all construction regulations were followed.

Closed Redlands facility and consolidated equipment and product from CA to Phoenix AZ, without service interruption, implemented preventive maintenance program on new equipment.

Made entire 3 facility campus profitable in under 1 year.

3M, Austin, TX Sep 1997 – Apr 2013

Multi-Site 10 years up to 14 locations at any given time.

Global Manufacturing Operations Manager (Fiber optics, clean room, injection molding, metal, extrusion)

Manufacturing and Operations Manager / 3M CMD (injection molding, Sonic welding, SMT, assembly)

Global Manufacturing Manager / 3M ESD Static (Fiber optics, injection molding, metal, extrusion, SMT)

3M Sourcing Specialist ECB (contract negotiation, supplier management)

3M EISD Plant Manager (injection molding, assembly, extrusion, metal, extrusion, SMT)

3M ESD Senior Engineer. (Metal Mfg, clean room operation)

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