RICHARD A. CHARLTON Hillsborough, NJ

Cell: 908-***-****

adc3hw@r.postjobfree.com

SUMMARY:

Solutions oriented Manufacturing Executive with expertise in manufacturing - engineered parts and machinery fabrication, plastic parts production. Experienced in operation management, manufacturing engineering, production planning, supervisory and technical staffing, team building, performance appraisals, ISO 9001-14001 and 13485, problem solving for production optimization, Lean Manufacturing concepts (6S, CI, Kaizen), warehousing / logistics, inventory and materials control.

Turned around a manufacturing operation.

Utilized tools of Lean Manufacturing and increased production 500%, managed 100% increase in organization.

Increased inventory accuracy to 99.9% cycle count efficiency, control resin to 2% monthly variance.

Extensive, multi-discipline manufacturing experience.

Experience includes plastic injection / blow molding and tooling, custom machine design and building, production machine shop, methods engineering, tool & die building, plant maintenance and capital equipment procurement, quality systems, warehouse, materials and inventory management, skills assessment, training design, production efficiency. Successful project management of the entire production cycle including customer requirements, product design, tooling development, production start-up, debugging, full production, packaging, warehousing and delivery.

Hands on production operations and management.

Managed all day-to-day manufacturing operations of a staff of 190 supervisory, technical, and hourly personnel. Initiated continuous improvement programs for entire manufacturing organization that increased profitability, productivity, quality and on-time delivery while reducing cycle, set-up and change over times. Union environment experience. Implemented workmanship standards for manufacturing personnel and QA departments. Developed procedures and policies that enhanced plant safety and worker morale.

EDUCATION:

BA in Business Administration, Lycoming College, Williamsport, PA

Computer software experience: MAPICS, Microsoft Office, Mattec, MFG-Pro, JDEdwards, SAP, Shoplogix, IQMS

Forklift and aerial lift operation certified

PROFESSIONAL EXPERIENCE:

Viant Medical, So. Plainfield, NJ

Operations Manager 2017-Present

Medical Devise OEM for major medical device manufacturers - $36MM, 24/7, 190 diverse personnel

Direct all production equipment, Toolroom, Maintenance and B&G functions.

40 injection molding presses in clean room class 8, assembly and staple forming operations.

Safety Teams facilitator. Designed “Safety Alert” system as well as “Preventative Safety Observation” program.

Union work force.

Consistently hold scrap to below 1.7% through continuous improvement and quality problem resolutions. When in doubt, shut it down and get help mentality.

BWAY Corporation, Dayton, NJ

Production Manager / Warehouse Manager (interim Plant Manager) 2012 - 2017

Rigid plastic container/packaging manufacturer - $72MM, 24-7 operation, 175 diverse personnel

Direct injection molding, blow molding, assembly and printing operations - 27 press, off-set printing, heat transfer and hot stamp labeling.

Directed warehouse, shipping and receiving operations.

Created a Safety culture that engages the entire plant personnel’s involvement - +600 days w/o a Lost Time, +475 w/o a recordable. Utilize STOP training. See something, say something, involvement in the correction approach.

Improved production OEE 5-7%, consistently in the +77% range, reduced scrap to below 2%.

Involved in developing, maintaining and sustaining GMP, HACCP, GFSI, BRC, and sanitation plans for food safety packaging lines.

Berry Plastics, Inc. Piscataway, NJ – Food, Personal Care, Pharmaceutical, Pet Care packaging manufacturer (formerly Captive Plastics, Inc.)

Warehouse Manager – Distribution Center 2004 – 2012

Managed a staff of 10 warehouse personnel for a 150,000 square foot warehouse with 5000+ SKUs.

Responsible for managing all shipping and receiving operations, and freight/logistics agreements. Initiated freight cost reduction programs.

Controlled all inventory and materials for the facility. Monitored and improved inventory accuracy by utilizing a continuous cycle counting program resulting in 99.9% accuracy utilizing JDEdwards. Controlled 10 silo and rail car resin inventories, approx. 3mil. lbs.

Directed all international shipping, logistics and documentation.

Continuously communicated with Customer Service, Supply Chain and Production departments to ensure on-time deliveries stayed above 99%.

Budget responsibilities for labor costs, production supplies, and fleet maintenance.

Upheld GMP, OSHA, SOP, DEP, AIB, HACCP standards.

Responsible for forklift fleet and dock maintenance.

Production Manager – Injection Molding & RHB Departments

Directed a 13 press injection molding operation and Sidel RHB operation – 24/7.

Directed a staff of 75 operations and shift personnel which included technical, production, quality, and maintenance.

Increased production in RHB Department by 30% while the number of changeovers tripled.

Documented procedural enhancements to increase productivity while lowering labor costs.

Budget responsibilities for labor costs and machine maintenance.

Active member of the safety committees.

Identified, designed and implemented many training modules.

Setco Inc., Monroe, NJ – Division of McCormick Packaging Group

Production Supervisor / Manufacturing Engineer 2001-2004

Stock and custom plastic bottle manufacturer – Injection molding, extrusion, stretch, injection blow molding of packaging for pharmaceutical, food, spice, personal care and specialty chemical industries.

Directed operations and shift personnel – technical, production, quality, maintenance, and warehouse.

Used Lean concepts to design work cells for efficient and profitable workflow with emphasis on cost and waste reduction.

Upheld safety standards, prepared job safety analysis for workers.

Philips Manufacturing Technology Center, South Plainfield NJ

Supervisor Equipment Construction / Project Manager 1996-2001

Successfully directed the construction of a $5.6 million assembly line - the largest single project in company history.

Responsible for project management, mechanical and electrical construction of capital equipment to customer/engineering specifications, upholding safety standards and codes, improvement modifications design, component parts fabrication.

Completed a Philips worldwide, 6 month, Shop Floor Management Program – Lean Manufacturing training.

Worked as a team member responsible for earning ISO 9001 and 14001 certification.

Coordinated equipment rigging, shipping, installation, start-up, and training at customer sites.

Directed operations of a Class 10,000 clean room for the building of semi-conductor machinery sub-assemblies.

Completed OSHA and HAZMAT training.

100 man Union shop, 20 in the equipment construction department.

Sussex Technology, Inc., Sparta, NJ

Production Manager / Manufacturing Engineer 1992-1996

Directed all manufacturing operations – 12 injection molding press, decorating, lining, assembly departments.

Directed a project utilizing custom assembly machine and robots. Annual labor savings of $75,000.

Upgraded material central blending system utilizing state-of-the-art gravimetric blenders and storage containers. Annual labor savings $20,000. Developed a raw material tracking program that reduced resin loss by 20%.

Initiated a recycling program, which reduced refuse costs by 80%, cost savings of $31,000 anually.

Tri-Tech Tool & Design Co. Inc., South Bound Brook, NJ

Production Manager / Manufacturing Engineer 1984-1992

Custom injection molders – electronics, medical device, moldmaking, engineering, machine building, and assembly.

Directed increase of manufacturing from a 1 shift operation to a 24 hour, 3 shift operation. Hired supervisory, technical, and hourly personnel. Doubled labor staff, increased production fivefold.

Designed and implemented manual and semi-automatic fixturing to increase production of electronic sub-assemblies by 80%. Annual production revenues increased $500,000 with no increased labor cost.

Designed and built production assembly machines, concept machines, and prototype injection molds.

Other Relevant Experience:

Phoenix Steel Drum, Manville, NJ – Toolmaker / Machine Builder / Machinery Maintenance – through college

Bridgewater Engineering, Bridgewater, NJ – General Machinist – through college

Zappa Tool & Mold, Greenbrook, NJ – Apprentice Injection Moldmaker

Zion Tool, Scotch Plains, NJ – Apprentice Injection Moldmaker - through high school

Forklift, man lift and powered equipment certified

First Aid certified

Contact this candidate