Supply Chain Plant Operations

Rick Janes – PLANT OPERATIONS – SUPPLY CHAIN – REGULATORY COMPLIANCE

Salado, Texas P.608-***-**** Email. ***********@*****.***

LinkedIn: linkedin.com/in/rickjanes

Business-driven Plant Operations and Safety and Environmental Compliance Leader, delivering outstanding returns managing and directing highly regulated Plant Operations to new and higher levels of performance. Operations Leader with strong analytical and problem-solving skills, implementing operational improvements, reducing costs and eliminating waste. Performance focused leader taking on the toughest challenges and delivering results through productivity and collaboration, resulting in bottom line profits and organizational excellence. Former US Army Captain 1988-1993. Gulf War Veteran.

Areas of Expertise

Food Manufacturing - Distribution - Plant Operations – Production - Process Improvement - Change Management

Safety Protocols - Regulatory Compliance – OSHA &EPA - Logistics - Quality Assurance –Project Management - Inventory Management - Strategic - Team Management - Budget Management - Planning - Employee Relations - Supply Chain - Financial Management - Materials Management - Revenue Generation

Drove TRIR, LTA, and workers’ compensation reductions in multiple sites by using leading metrics and establishing employee training and engagement.

Achieved largest grand mean score increase (0.69 points) at SunOpta by enhancing employee engagement; authored a non-exempt performance process highlighting and measuring desired behaviors that was adopted companywide.

Established Master Operating Systems in multiple sites to further employee engagement, reduce costs and improve overall production.

PROFESSIONAL EXPERIENCES CAREER HISTORY

REFRESCO, Waco, TX 2022 - 2023

Overall responsible for the execution of a co-manufacturing contract to package Coca Cola products in a complex environment. Technologies included: Blow molding, hot fill, cold fill, aseptic and low acid aseptic production over ten production lines and two variety pack lines utilizing four hundred associates and an 800K square foot facility. Managed on and off site ambient and cold storage facilities yielding shipments of up to one hundred sixty trucks a day. Factory Director

Managed the only OSHA VPP site in Refresco. Achieve TRIR 0.3 by implementing leading indicators and employee led initiatives. Workers’ compensation reduced by 300%. No lost time accidents and only 1 injury during my tenure.

Reduced consumer complaints by 30% utilizing data to create more robust CIP cycles and execution.

Negotiated $1M in reduced contract spend and managed overall reduced variable spend by $1.7M in 2023.

Achieved 99.9% inventory accuracy in finished goods, materials and spare parts.

Implemented Master Operating System (MOS) to drive continuous improvement and employee engagement. The first plant out of eighty plants to execute this initiative.

RUSSELL STOVER Iola, KS 2021 - 2022

Led a plant of three hundred associates specializing in small batch confection production. Production technologies included confectionary bar, starch molding, and press molding. Launched the first Kansas of Department Corrections employment program for Russell Stover by employing eighty female inmates over three shifts to address labor shortages. Left to be located with my family in Texas.

Plant Manager

Led initiatives to reduce injuries and increase regulatory compliance by developing training and pre-operation checklists to drive accountability down to the operator level. Reduced TRIR by 400% and LTA’s from 8 to 0 in a year.

Reduced material write-offs by $800K by re-organizing material locations and implementing sound reconciliation practices.

Created a line prioritization and line relief process to increase production by 20%. This was generated by implementing a line relief crew and specialized training to increase overall skill set and execution.

REMBRANDT FOODS, Spirit Lake, IA 2020 - 2021

Overall responsible for live production and conversion of aseptic, bulk liquid and spray dried egg in conventional and cage free egg production. Managed multiple internal pullet and layer locations as well as contract producers. Business closed due to AI.

Vice President of Operations

Reduced cost of egg by $0.04/lb. by decreasing feed conversion and increasing overall production through in liquid as well as dried egg throughput.

Reduced restricted inventory by $3M by increasing right the first-time production by 20%

Increased on time in full metric from 78% to 89.5% by creating supply chain tools to better align sales and operations.

MYCOTECHNOLOGY, Aurora, CO 2018-2019

Managed a 4,000 MT bioconversion plant using shitake mushrooms as the basis for fermentation, including team development, process improvement, and build-out of the manufacturing space. Low sales led to a reduction in force.

Plant Manager

Led operational support to develop safety and quality protocols for production of cutting-edge ingredient while establishing standards and guidelines that aligned with company vision.

Innovated predictability of fermentation batches by establishing baseline KPI’s and conducting capability studies. Accelerated onboarding and training process by developing comprehensive operational and safety standards. Facilitated cross-functional collaboration for unified cooperation during construction, startup, and production phases.

KEMPS, Rochester, MN 2016-2018

Managed a 32-million-gallon milk plant responsible for delivering 400+ SKU’s on a weekly basis, including a variety of fat levels and packaging options. Oversaw financials, team development, production, safety, quality, maintenance, thermoforming, and capital projects. Plant closed due to asset consolidation with DFA.

Plant Manager

Lifted on-time-in-full (OTIF) metrics 15% by implementing new inventory control software and cooler optimization. Cut total recordable incident rate (TRIR) from 15.8 to 1.3 via employee engagement and process/safety improvements.

Improved environmental health trend results by increasing focus on CIP validations (hygiene inspections) and sanitation work order compliance; increased shelf life in 25% of the products produced as a result. Lowered overall conversion costs by $0.025 per gallon, resulting in a positive budget variance of $1.3M. Led teams in earning “best plant” recognition and governor’s award for safety results.

SUNOPTA, Crookston, MN 2014-2016

Led a multi-plant vertically integrated operation that processes sunflower seeds, overseeing financial results, safety, quality, production, logistics, third-party warehousing, and employee engagement. Laid off due to private equity purchase of business

Plant Director

Improved profitability $3.5M by implementing continuous improvement programs that unlocked capacity, increased yield, and enhanced inventory accuracy, resulting in $5M financial improvement over a two-year period.

Captured a significant increase in OTIF metric, lifting from 65% to 95% by establishing a production planning process. Cut worker’s compensation costs $100K and sustained operations with no lost time accidents for more than two years.

SENSIENT FLAVORS, Juneau, WI 2011-2014

Directed a 20-million-pound per year yeast extract spray drying facility, overseeing site safety, budgeting, capital planning, logistics, labor relations, and scheduling for a 24/7 plant.

Plant Manager

Achieved SQF level 3 certification by revising plant HACCP plan, instituting a food safety plan, and setting the foundation for a $25M capital investment of a pharmaceutical grade tower dryer and a 30% production increase.

QUALITY INGREDIENTS CORP, Marshfield, WI 2010-2011

Headed strategic and change initiatives, site safety, financial performance, quality, and logistics for a $60M operation producing 54 million pounds of dairy and non-dairy creamers, accounting for 80% of company profits. Plant sold and business consolidated

Plant Manager

Saved $200K+ and achieved >99% customer satisfaction rate after conducting a financial assessment and pioneering the initiative to maintain 24/7, in-house production as opposed to outsourcing during historical slow months.

Cut downtime 10% during changeover periods and saved $100K in labor costs by incorporating Lean operations across the facility; generated an additional $50K in labor savings by installing automatic tote packaging system and palletizer.

MASTERFOODS US / M&M MARS, Waco, TX 2000-2010

Directed a large confectionary plant producing 200,000 metric tons of products each year for a multibillion-dollar manufacturer while overseeing safety, environmental reporting, process improvement, wastewater treatment, sanitation, and logistics.

Operations Manager

Slashed workers compensation costs 250% and captured total recordable rate of 3.0 vs 6.0 (OSHA) and lost-time injury rate of 0.2 vs 3.5 for OSHA and 0.35 companywide. Led team in achieving ISO 22000 PAS 220 Certification.

Implemented Lean strategies, increasing productivity 20%, cutting labor costs $1.2M, and reducing on-hand stock $4M. Captured $4M in annual cost savings after facilitating capital installations of new material receiving assets; renegotiated vendor contracts to recover an additional $800K.

Lifted plant efficiency from 72% to 76% and improved customer service metric from 93.2% to 98.5% while transitioning from a seven-day schedule to a five-day calendar.

Prior roles include Business Unit Manager, Oscar Meyer Division and Safety & Environment Manager for Kraft Foods.

EDUCATION

BS, Biology (Minor in Chemistry) – St. Norbert College, DePere, WI. 4-Year Army ROTC Scholarship Winner

U.S. Army Captain 1988-1993. Gulf War Veteran.

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