Edward Buzulak

Harrisburg, PA ***** 717-***-**** Mobile addygs@r.postjobfree.com

Manufacturing Manager/Continuous Improvement Leader

Progressive manufacturing leader with more than 20 Years of experience in Operations in developing high-performing teams and implementing continuous improvement processes. Experience in high-volume manufacturing plant operations. Identify opportunities by developing value stream mapping. Implement Lean Management systems, and hands-on “through the ranks” experience in all aspects of the manufacturing process.

Areas of Expertise

Lean Management Initiatives OEE Improvement Coaching and Mentoring

DMAIC Strategies Waste Reduction/DMAIC Strategy Team Building

Manufacturing Leadership Audits/Performance Management 5S Implementation

Cellular Manufacturing Continuous Process Improvement Kaizen Improvement Events

Value Stream Mapping Measurable Performance Standards TPM

Professional Experience

EXTRUSION BUSINESS SYSTEM MANAGER Feb 2016 - Current

Hydro Extrusion

Launched introduction of Lean Manufacturing tools that transformed the culture and processes of a 1,000-member facility.

Implemented and maintained a sustainable focused improvement (FI) team program.

>Identified systems problems and required modifications to achieve cost effectiveness, time saving, and least disruptive solutions to optimize the system.

Improved 5S plantwide through a systematic approach to workplace organization.

Introduced an A3 Strategic and Project tracking system

Highlights:

Achieved $8 million in cost savings through Lean initiatives over a two-year period.

Reduced inventory requirements by 50% by implementing an internal Kanban system.

Cut maintenance downtime by 6%.

Improved manufacturing homogenization process by 25%.

Led DMAIC teams to reduction of 200 hours of machine downtime and sustained 95% reduction in three months.

Organized cross-functional team, applying DMAIC process, audit program, and visual management tolls to resolve major quality issues in Die Casting operation.

>Reduced raw material purchase cost by 35%.

>Alloy-off analysis was reduced by 90% to improve quality.

>Audit scores improved from 68% to 92%.

CONTINUOUS IMPROVEMENT MANAGER Mar 2014 – Feb 2016

Serta/Simmons Bedding

Implemented TPS Heijunka production leveling plan to prevent fluctuations in production and produce goods at a constant and predictable rate.

Led safety culture to achieve top ten SSB performance.

Highlights:

Led transformation of physical facility layout in two departments that improved flow and efficiency by 19% and reduced need for overtime by 15%.

Achieved year over year safety improvement of 8% by conducting Lean Safety Gemba walk through the work area focusing on continuous improvement of safety engineering and practices.

Reduced downtime within six months by identifying causes of customer delivery misses, overtime, and defects, and reduced quality issues by 38% by providing value stream flow improvements.

EDWARD BUZULAK – Page 2

717-***-**** Mobile addygs@r.postjobfree.com

OPERATIONS MANAGER Sep 2012 – Feb 2014

Amazon - Carlisle, PA

Led two area managers and three frontline supervisors with 100 hourly associates in inbound operations with the Fulfillment Center.

Managed safety, quality, performance, and customer experience in the shift.

Strategically planned, evaluated performance, provided rewards and discipline, and resolved problems to meet and exceed operational goals.

Highlights:

Developed inbound training and cross-training programs to develop shop floor personnel with little previous experience, improving productivity by 30% within three months.

Achieved 25%-35% gain in productivity hours by simplifying processes and reducing waste/

Improved IB doc flow by 10% by improving communication.

Improved pick percentage and reduced quality errors by implementing new slow strategy in drop zones.

LEAN MANUFACTURING EXPERT Jan 2010 – Jan 2012

Honeywell Inc, - York, PA

Provided guidance and support in Lean manufacturing, Kaizen, performance metrics, plant layouts, standard work, cellular layout, Value Stream Mapping, and plant cost-reduction initiatives.

Implemented Lean manufacturing and TPS throughout a $112 million process plant.

Championed a continuous improvement culture and implemented Kaizen employee suggestion program.

Highlights:

Implemented Kanban inventory system with suppliers that streamlined inventories by 50%, improved customer delivery performance from 85% to 93%, and reduced lead times by 60%.

Identified and eliminated $40,0000 in process WIP by adopting team-based value stream mapping.

Reclaimed 28% of floor space for new product implementation through Lean initiatives.

Caused transformation of production methodology, saving $500,000 from a push system to a pull system for cellular manufacturing.

LEAN SPECIALIST Jan 2006 – Jan 2010

General Electric Grove City, PA (2006 to 2010)

Implemented Lean for 800-person, three shift facility, created Lean education program, and led Lean improvement fabrication team of 8 people.

Highlights:

Reduced fixture changeover time from 63% to 85% for CNC and horizontal grinding/finishing machines.

Improved process efficiency by 20% to 68% by redesigning machining cells and creating flexible floor space.

Trained Lean Team Leaders with hands-on practice and a new Lean Certification program.

Led nine-member Lean Improvement fabrication team leading to $500K yearly savings by creating parts, conveyer, pneumatic, and sandblasting systems leading to significant savings.

MANUFACTURING MANAGER Jan 1994 – Jan 2006

Dana Corporation – Toledo, OH

Led 50-person department as manufacturing manager: managed safety, quality, performance, & customer experience in the shift.

Led 20-person team as area supervisor, responsible for safety, quality, performance, and production.

Managed Lean implementation for 300-member two shift facility, transforming from push to pull system.

Highlights:

Led over 50 Kaizen events for assembly and machining facilities, reduced changeover time by 50%, saving $2.8 million.

Education & Certifications

Bachelor of Science in Elementary Education - Slippery Rock University of Pennsylvania

Honeywell Certified Lean Expert, 2013 / Honeywell Certified Green Belt, 2012

GE Certified Core Black Belt, 2009

Dana Certified Black Belt, 2004 / Dana Certified Green Belt, 1998

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