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Plant Manager Employee Relations

Palm Coast, FL
February 26, 2020

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Robert L. Horn

* ****** *****

Palm Coast, Florida 32164



Senior Executive

Manufacturing Continuous Improvement Expert

Excellent Business Acumen – Enterprise-wide Lean Transformation • P&L Performance

100+ Kaizen Events • TQM • Team Leadership • Equipment Strategy Workshops

Manufacturing and Transactional Implementations – Trainer / Mentor

Manufacturing Methodologies – Toyota Lean Training and Implementation • Six Sigma BB

Lean Sigma and Continuous Improvement • Kaizen / TPM • Kanban • 5S & Visual Plant

Cellular Manufacturing • Flow Manufacturing & POU Storage • Safety Programs / Multi Plant

Training Workshop Leader - Operator Care –Turnarounds - ISO 9000 –

Logistics - Total Productive Maintenance - Quality

Industry Experience – Foods & Consumer Goods • Metal Fabrication and All Types of Welding

•Painting • Foundry and Casting • Plastic Injection Molding and Forming

Wood Case Goods Industry • Automotive Tier 1 – Unions

Recent Experience, Key Challenges and Results:

Bob Horn Professional Business Advisor, Palm Coast, FL. – 2015 to Present

Providing Assistance to companies for growth and profitability. Although a rewarding and successful endeavor, I would like to concentrate my efforts on a single company fulltime.

Certified Professional Business Advisor

Implementing projects at companies to increase Profits, Growth, Market Share and Viability

Textron - 3 months - Rotated & Zoned Warehouse, Reduced Orders Fillers 50%, Caught up 6 week backlog in 2 weeks. (Jacobsen Products) Upgraded Maintenance Training

Konica – 2 months – Reduced Lab SQFT, Implemented 5S

Morton Custom Plastics, interim Plant Manager 12 Months

Klipsch - Developed Outdoor Plastic Speaker Line 8 Months.

Serta – 4 Months - Renovated Warehouse Facilitating Better Truck Loading, Designed Memory Foam Mattress Line, Redesigned Base line reducing assembly time from 2 Min. to 40 Seconds, Improved Quality 20% via Standards & Inspection. Started off shift Maintenance

TI Automotive Fuel Handling Division, Vance, Alabama - 2012 to 2015

Manufacturer of Plastic Blow Molded Gas Tanks for the Automotive Industry, BMW, Nissan, VW, Mercedes

Plant Manager

Project Coordinator for new Plant start up supplying Mercedes Benz Plant with 1 assembled and tested Blow Molded plastic fuel tank every 3 minutes

Incorporated 3rd party labor staffing paying on a per-piece basis instead of hourly

Managed All Incoming and Outgoing logistics and set-up JIT hourly delivery

Designed Material Handling System saving Mercedes $1mm annually

Managed Fleet of 5 delivery trucks in service 24/7

Implemented Hand Off Shift Change allowing non-stop manufacturing during shift change

Sara Lee Food and Beverage, Storm Lake Iowa – 2009 to 2012

Manufacturer / Processor of Turkey Meat and By Products

Continuous Improvement Manager

Manufacturer / Processor of Turkey Meat and By-Products

Directing all Continuous Improvements and Lean initiatives within the 2 plants and suppliers. Achieved cost reductions and improvements exceeding $3MM for FY 10.

Developed 5 plant closed loop plastic pallet system saving $350k annually

Reduced Employee Turn-over from 70% to less than 32% by taking Candidates on a Plant Tour “Before” hiring.

Implemented TPM and Operator Care Training taking weekly OEE from 85% to 98%

Performed Problem Solving / Kaizens to achieve 99.5% OEE and $3.5MM annual cost savings. Items such as picker finger material change and “Operator Care”.

Highland Industries / Takata, Kernersville North Carolina - 2008 to 2009

Manufacturer of Fabric and Air Bags Contract Position

Continuous Improvement Project Manager

Directing Lean Manufacturing in assembly and test cells

Reduced Test Cell Set Up Time through Air Clamp System

Improved Air Bag Folding with Ladder Style Folding Clamp

Implemented Additional Safety Equipment in Igniter Loading Cell

Relocated TM Laser Cutting Table for Traffic Flow through Plant.

Kimball Electronics / Jasper, In - 2007 to 2008

Electronic Parts Manufacturer Contract position

Continuous Improvement Project Manager

Directed the launch of new products as well as assisting engineering with material choices.

Performed Lean training for Electronics Team

Launched custom CPAP respiratory recorder under budget and ahead of schedule.

Replaced faulty material that was generating warranty claims.

Performance Trailers, Inc / Clearwater, FL – 2004 to 2007

Multi-plant Manufacturer of custom galvanized and aluminum Marine / Utility trailers serving the Eastern US.

Operations Manager

Complete Lean Implementation of new facility. Directed manufacturing and distribution. Implemented safety, quality, and productivity improvements with P&L responsibility for 100 person manufacturing facility. Customer base including both marine dealerships and boat manufacturers.

320% Through-put improvement in 90 days,

95% quality improvement in 120 days.

Reduced Inventory 15% through part redesign incorporating multiple parts into one bi-polar assembly.

Assembly Line Improvements through Training, Operator Aids and Lean Manufacturing.

Cut Warranty Claims 50% through quality inspection systems, training, and empowerment.

Manufacturing Extension Partnership / NCSU, Raleigh, NC – 2000 to 2004

Nationwide Federal system of services and support for Manufacturers to become more profitable and competitive.

Lean Master / Certified Professional Business Advisor

Assist North Carolina companies with implementation of Advanced Manufacturing Techniques, Continuous Improvement and Lean Manufacturing to increase profitability and growth

Implementation Champion performing multiple corporate Lean transformations

Member of small elite Certified group coaching top management of diverse companies and implementing Lean Programs.

Managed multiple projects simultaneously, working with such companies as Douglas Battery, Textron, General Dynamics, and Morton Metalcraft to implement Lean Transformation.

Education / Professional Development

BS, Industrial Design Engineering Technology, University of Cincinnati

Member of Cambridge Who’s Who

Member of Society of Industry Leaders

Society of American Value Engineers


Toyota Production Systems

Flow Technology, Kaizen

Synchronous Manufacturing

Paint & Powder Coating

ISO, TPM, QS, JIT, MRP, SPC, VSM & ERP, SMED, 5S, 8 Wastes


Lean Master

Six Sigma BB

Value Engineer

Strategic Planning

Professional Business Advisor

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