Plant Manager

Location:

Maricopa, AZ

Posted:

August 17, 2020

Contact this candidate

Resume:

THOMAS D. KU

***** *. ****** **

Maricopa, AZ ***38

(949) 300- 9209

******@*****.***

Skype; thomas.ku3

EXPERT OPERATION/MANUFACTURING MANAGER

OBJECTIVE Seeking a highly challenging upper level Manufacturing Management opportunity

EDUCATION Bachelor of Science Degree in Mechanical Engineering Mechanical Engineering

California State Polytechnic University, Pomona California State University, Fullerton

August 1984 - December 1987 June 1982 - June 1984

AREAS OF EXPERTISE

Leadership/ Management Top Line Growth Operational Excellence

Safety Programs New Business Development Optimized Work Force

LEAN/Kaizen/5S Capital Projects / ROI Capacity / Productivity

P&L / Budgeting New Product Introductions Cost Reductions

Six Sigma Organic Growth / Build Ground Up Engineering/Maintenance/Process

Develop Management Teams Extrusion/Molding/Packaging Environmental/Quality ISO/Class 100,000

Supply Chain Custom Order Optimization

Human Resources SAP, AS400, JDE, OSHA

Strategic Planning WebEff, Matec, GDC

Acquisition/Integration

Plastics, Corrugated, Pharma, Wood

EXPERIENCE

Plant Manager

Parker Hannifin

Tucson, AZ (2020)

Parker Hannifin is a Fortune 250 global leader in motion and control technologies. Tucson Veriflow division serves the semiconductor industries offering PFA & PTFE molded and machine components for gas and fluid controls. Company is a $15B operation with over 300 facilities globally. Tucson's operation generates $20M annually with focus in doubling the revenue in the next 5 years. Processes include injection molding, CNC and assembly (75 total employees). A turn around situation involving realignment of staff and increasing labor capacity. Accomplishments are as follows;

●Re-alignment of senior leads in all departments

●Implemented Zero Safety Tolerance program

●Developed a COVID task force to ensure exceeding CDC safety protocols

●Labor capacity increase by 23% via time studies, TAK time, automation and Kaizen Events

●Achieved all key metric goals for FY20 Q3 & Q4... zero recordable, Net Margins, 98% OTD, 0.3 % customer returns, 89% OEE

●Developed a robust scheduling process to ensure build plans met quantity and revenue targets

●Improved overall employee satisfaction score by 23%

●Involved in purchase negotiations and driving a 10% reduction initiative with outsourced supplies

●Full P & L responsibilities

(lay off due to COVID business loss impact)

Plant/Ops Manager

Berry Global

Lathrop & Anaheim CA (2017- 2019)

Berry Global Group, Inc. manufactures plastic products and containers. The Company produces plastic films, medical specialties, closures, overcaps, tapes, tubes, bottles, drink cups, lids, and trash bags. A global giant operating worldwide with an annual revenue reaching $8B. Primary processes are rotational injection blow molding, printing and labeling (250 total employees). Focus responsibility is to utilize turn-around expertise to enhance the business operation to exceed expectations. Accomplishments are as follows;

Re-aligned employee talent utilization and accountabilities to drive World Class Performance

Developed multiple Kaizen Teams to improve equipment and mold efficiencies along with Kaizen Scrap Reduction Team and Kaizen Cycle Time Reduction Team

Re-ignited Safety and Quality Programs

Renegotiated resin purchase agreements in driving a 7% cost reduction initiative

Enhanced employee engagement and empowerment to further improve facility Culture

Introduced 6S program to drive safety, organization and housekeeping

Enhanced customer satisfaction via developing close communication and business relationships

Developed 2018 Budget and CapX along with Cost Reduction Initiatives to improve by EBITDA by 20%

Full P&L responsibility to exceed budgeted EBITDA

(Mutual separation)

Plant Manager

Inteplast Group/Amtopp Phoenix

Phoenix, AZ (2014 – 2017)

Through three divisions—AmTopp, Integrated Bagging Systems (IBS), and World-Pak— Inteplast manufactures a synergistic and diverse product line that includes stretch films, BOPP films, plastic bags, PVC sheets, and virgin pellets. Inteplast is recognized as the top 3 North American Film Manufacture with +$2B in annual revenue. Processes included cast film extrusion and converting ( 70 total employees). Responsibilities include the establishment and start-up of their first West Coast facility. Accomplishments to date are as follows;

Establish & develop a brand new 500,000 sf stretch film manufacturing facility

Collaborated with contractors to install cast extrusion and film converting lines as well as support equipment

Developed all operational programs (AS400 setup, production operations, safety, quality, purchasing, logistics, maintenance, stocking levels & purchasing)

Hired key employees (office, shipping, production & maintenance)

Developed and tracked KPIs (lbs output, yield & downtime)

Developed a sustainable 5S & TPM programs

Began production within 2 months of construction initiation

Cost Reduction initiatives to standardize corrugated packaging

Ultimately developed a Flag Ship Plant for the organization

(Resigned due to family situation)

Plant Manager

Exopack

Ontario, CA (2012 – 2013)

Exopack is strategically positioned to handle the needs of customers with 11 plastic, 6 paper and 2 coatings facilities with an annual revenue of $700 MM and offers one of the broadest product offerings in the flexible packaging and film coatings industries. Ontario utilizes raw materials such as HDPE & LDPE. Managed 7 direct reports and 70 indirects. Processes include blown film extrusion, printing and converting. Production work orders are all custom orders. Significant accomplishments are as follows:

Enhanced Safety Program to deliver short term and long term goals (Personally led Safety Committee)

Developed Behavior Observation Program (BOP) to improve Safety behavior

Formulated a waste reduction program to deliver 5.5% improvement and resulting in an annual savings of $1.2MM

Improved labor utilization efficiency resulting in an annual savings of $390K

Extensively utilized LEAN/KAIZEN/TPM /CMMS to improve KPIs (Pounds/hr, Waste % & OT %)

Developed and led a 5S program

Improve Quality System to reduce customer returns yielding an annual savings of $900K

Total annual EBITDA improvement of $3MM annually

Improve custom order optimization by way of enhanced production schedules

Enhance employee involvement in various performance improvement initiatives as well as mentoring direct reports

Letter of recommendation from Division President & VP of Sales available

(Lay off due to restructuring)

Operations Manager

JM Huber

Modesto, CA (2011- 2012)

Huber Engineered Materials is a $2 Billion global leader in specialty inorganic PHARMACEUTICAL powders such as silicates, alumina trihydrate, magnesium hydroxide, barium sulfate and calcium carbonate (includes food and USP grades). Innovative materials enhance hundreds of products—from cosmetics to countertops, from toothpaste to industrial coatings for bridges and ships, from paper coatings to pharmaceutical excipients. Key responsibilities are as follows; Manage operation to support business strategies, achieve company targets and budget objectives. Safely and efficiently manage the plant operation in order to meet or exceed customer requirements. This includes the technical, physical, and human aspects of plant operations, plant safety, plant environmental, plant engineering, and plant maintenance. Following Huber’s EH&S, CMS, SOP, cGMP and company policies and procedures is essential to this position. Oversee compliance of all production employees. Managed 5 direct reports and 50 indirects.

Key accomplishments are as follows;

Developed KPIs (Key Performance Indicators) and improved visibility to all levels of operation

Developed a Focus Team to resolve major efficiency issues (particle size & micro bacteria)

Initiated a program to update Batch Records

Optimized custom orders to improve production efficiency

Utilized 5S methodologies to improve housekeeping

Safety champion to ensure zero workplace accidents and injuries (Led Safety Committee)

Ensure quality compliance to Nutrition Compliance Management System which includes FDA 21 CFR 111/211 & Q7A

LEAN methodologies (Kaizen Team) to improve changeover duration which included implementation of a dry ice cleaner

(Plant closure)

Director of Operations

Precision Science

Scottsdale, AZ (2010 - 2011)

Precision Science is a leader in the manufacturing of FDA regulated PHARMACEUTICALS as well as EPA products in the animal healthcare industry with an annual sales of $20MM.

Responsibilities are as follows; Ensuring FDA/EPA compliant manufacturing, Developing and leading the manufacturing operation including manufacturing, supply chain/materials, shipping/receiving and facilities departments as well as ensuring cGMP compliance of the roles, activities and proceedings of all assigned manufacturing personnel. Majority of orders are custom made to order.

Managed 4 direct reports and 25 indirects.

Key accomplishments thru LEAN are as follows;

Developed KPIs (Key Performance Indicators) tracking mechanisms and implemented Kaizen to improve OEE (Overall Equipment Effectiveness) by 12%

Developed and led a Safety Committee resulting in Zero Injuries for rolling 10 month period

Transitioned the Preventative Maintenance program to a CMMS (Computerized Maintenance Management System)

Developed a highly effective manufacturing scheduling system to reduce overtime from 17% to zero

Managed key projects to ensure FDA compliance

Introduced automation and effectively eliminated all temporary employees

Developed and drove key strategic plan to ensure business growth readiness

Direct hands-on development of new products to further increase revenue and EBITDA

Development of POP, corrugated packaging

Updated all SOPs and GMP

(Resigned due to family issues)

Tekni-plex Corporation (2006 – 2009)

Plant Manager

Natvar (Division of Tekni-plex Corporation)

City of Industry, CA (2008 to 2009)

Transferred to the medical tubing division of Tekni-plex in a Plant Manager capacity with multi-plant responsibility. This division is noted as a leader in tubing extrusion technology for the medical and industrial markets with annual sales of $60MM. Specialized tubing applications under a ISO 13485/Class 100,000 clean room are as follows; intravenous therapy, cardiovascular procedures, urinary drainage and catheterization. Majority of raw materials utilized are as follows; PE, PVC, thermoplastic polyurethane (TPU), polystyrene and ABS. Managed 12 direct reports and 130 indirects.

All orders are made to order. Significant accomplishments are as follows:

$800K annual labor savings by reducing the temporary headcount from 40 to 20