Operations Manager, Plant Management, Continuous Improvement

Jason C. Calkins

**** ******* **., *********, ** 35150 * cell: 256-***-**** * email: *******.*****@*****.***

Professional Summary

Production Manager with over 27 years of proven experience in manufacturing and continuous improvement. Assertive and proactive individual with a self-evident sense of urgency to analyze, identify and solve problems in a dynamic, fast-paced work environment with an emphasis on collaboration and teamwork.

Skills

Lean Manufacturing

Six Sigma

Continuous Improvement

Value Stream Mapping

SPC, DoE, Poka-Yoke, SMED, Kaizen

Process Engineering

Visual Management and 5S

SQDC, KPI, PFMEA, Gap Analysis

Process and Work Flow Optimization

PDCA, DMAIC, TPM and TQM

5-Why, 5P, 8D, Root Cause Analysis

Project Management

Training and Team Building

Production and Inventory Control

QS/ISO: 14001 and TS/IATF: 16949

EHS, ADEM and OSHA Compliance

Education and Certifications

P&L, Balance Sheet and Financial Statement Certificate, Pryor Seminars, 2017

Lean Six Sigma Green Belt, Auburn University, 2004

Business Studies, Central Alabama Community College, 1988-89

Work History

Production Manager Tru Cabinetry, LLC February 2020 – April 2020

Directed and developed the facility’s Sanding and Finishing departments on 2nd shift

Recruited, mentored and coached associates to rebuild a successful team dynamic

Reduced paint waste from ~$5,000 to ~$1,600 per week by developing a structured method to mix smaller batches, resulting in annualized cost savings of $176k

Developed an assessment program to grade associate skill levels, identify training deficits and incentivize internal promotion

Production Manager Unipres Alabama, Inc. 2017 – 2020

Managed the Press, Tooling and Hot Stamp departments for a Tier 1 automotive supplier

Motivated team members to meet or exceed safety, quality, cost and delivery objectives

Encouraged and mentored team members through training, evaluation and feedback; established a line of succession whereby key positions could be filled internally with well-qualified candidates

Submitted and strictly adhered to departmental budgets and manpower requirements with emphasis on cost reduction through continuous improvement

Reported monthly KPIs based on target vs actual and conducted gap analysis to focus key resources on areas for improvement

Upgraded data collection to separate die-related vs equipment-related downtime; slashed equipment-related downtime on the 3000-ton transfer press over 60% the first year

Remodeled the die maintenance spare parts crib to stock critical parts by die, reduced lead times and eliminated 85% of downtime associated with lack of spare parts

Instrumental in the company’s successful transition to IATF: 16949

Operations Manager Fleetwood Metal, Inc. 2006 – 2017

Operations Manager of a Tier 1 automotive supplier specializing in metal stamping, resistance welding, robotic spot welding, robotic MIG and value-added assembly

Managed all aspects of production from receipt of raw material, inventory control, production scheduling, logistics and shipping

Trained a hand-picked production control team to generate production schedules, manage outsource suppliers and conduct cycle counts at all levels to ensure inventory accuracy

Created a skill assessment and evaluation program for new hires to prompt training, monitor progress and identify training deficits for improvement

Initiated and led numerous projects to implement 5S, Lean Manufacturing and Visual Management throughout the plant

Used Lean Six Sigma and Kaizen breakthrough methodology to drive continuous improvement, improving labor efficiency from 58 to 81% and OEE from 46 to 77%

Revamped the company’s physical inventory count to define specific team roles and responsibilities; reduced inventory variance from $150k to $10k in the first year

Reduced raw material inventory (steel coils) by $3m annually by working with suppliers to right-size coils to desired run size and micromanaging daily release schedules

Production Manager Nemak USA (formerly Teksid Aluminum Components) 2005 – 2006

Production shift manager responsible for direct oversight of a Tier 1 automotive supplier specializing in HPDC (high pressure die casting), machining and air decay leak testing

Managed all aspects of plant operations from receipt of raw material, production planning, quality sampling and shipping

Coached supervisors and team leaders to meet or exceed SQDC objectives

Production Supervisor Nemak USA (formerly Teksid Aluminum Components) 2000 – 2005

Production Supervisor of a Tier 1 automotive supplier which produced aluminum cylinder blocks and cylinder heads using lost foam technology

Charter member and first promoted supervisor for the plant’s foam molding department

Recruited, trained and developed a new work force for the start-up of the new facility

Military Service

Airborne Infantryman, 82nd Airborne Division, Fort Bragg, NC, 1996 - 1998

Outstanding Honor Graduate from Basic Training in Fort Benning, GA, 1996

Re-tasked to company operations following an injury sustained during an airborne exercise; responsible for all administrative duties of a 160-man airborne infantry company

Received ARCOM (Army Commendation Medal) for coordinating and achieving the highest standard of excellence for Brigade ORS (Operational Readiness Status) audit

Honorable Discharge (DD-214 available upon request)

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