A highly successful operations leader with a proven track record of improving all aspects of manufacturing; from supply chain to shipping. A quality and safety minded driven leader
LKQ / Keystone Corp.
2017 to Present
LKQ is a Fortune 500 company that specializes in the various automotive industries, including refurbishment, recycling, and after market sales.
Responsible for the financial performance of 8 locations in Texas, Louisiana, and Ohio
Direct plant managers in all activities required to accomplish company and personnel goals
Set budgets for each location based on market conditions, past performance, and future expectations
Determine price structure for parts and materials based on needs, demand, and market conditions
Negotiate with suppliers to achieve best pricing, resulting in reduced costs, saving the company $1.4mm
Develop training program for plant managers to strengthen their overall business acumen
Implemented best practice program across all plants, resulting in lower fixed / variable costs, and increased throughput, resulting in an additional $10mm bottom line performance over a 3-year period.
Increased EBITDA by 4% in 2018, 3% in 2019, and 7% in 2020
Forge USA, Houston, TX
Director of Manufacturing Operations
2014 – 2016
Forge USA specializes in the manufacture of Forged and Machined products for the Oil and Gas industries, manufacturing parts ranging in size from 100 lbs. to 50,000 lbs.
Responsible for the day to day operations of two individual manufacturing plants; Forge and Heat Treat located in Houston TX, and Machining located in Brookshire TX.
Full P&L financial responsibility for both facilities, including fixed and variable cost, budgets, and operational profit.
Implemented safety program resulting in zero lost time accidents in 24 months
Created and standardized operational metrics for all departments, including; OTD, Safety, Quality, Productivity, Throughput, earned hour calculations, and cost per earned hour performance. Resulting in improved OTD by %82, reduced COPQ by %53, and reduced cost per earned hour by %41.
Implemented multiple best practice programs in all departments, creating SOP’s and visual work instructions for complicated and or technical operations / processes.
Started manager training program to increase business awareness, improved team understanding of goals, and increased morale and cohesion between departments.
Developed and launched 5S program, increasing throughput, and reducing WIP volume by %38.
AFGlobal / Ameriforge, Houston, TX (Fabrication and Assembly Plant)
General Manger 2012 - 2014
Plant Manager 2008 - 2012
Specializing in the manufacture of turnkey products for the Oil and Gas Industry, including sub-sea Drilling Riser, Telescopic Joints, Gas Handling Systems, Frac Skids, Separation Units, Flow Meters, and similar type fabricated products.
Full P&L financial responsibility for the operation accounting for $350mm of revenue with the highest bottom line EBITDA performance in the company.
Responsible for the day to day operations and performance for 300 employees across the direct operations of: Welding, Quality Control, PWHT, Paint Line, Assembly, Testing, and the indirect operations of: Supply Chain, Quality Assurance, Scheduling, Project Management, Purchasing, Shipping and Receiving.
Reduced the need for 3rd party suppliers by implementing in house coating, testing, robotics, and welding, reducing lead time by 400% with an annual cost reduction of $1.5mm
Led the plants first ISO certification initiative, and brought the company to ISO certification and API compliant during the first year. Well versed in API / ASME / ASTM codes and specifications.
Established daily reviews with direct reports of internal financial, production, quality, and safety performance, using data driven metrics to drive improvements at the floor level.
Implemented staging areas, tool boards, visual work instruction / job notification tables. Also implemented Kaizen, 5S, Tool Box Talks and daily housekeeping to improve employee productivity and retention.
Implemented monthly Safety Training program, which contributed to setting new plant records for days without a loss time accident.
AFGlobal / Ameriforge, Houston, TX (Forging and Machining Plant)
General Manger 2012 - 2014
Plant Manager 2007 - 2012
Engineered Products Manager 2005 - 2007
Specializing in the manufacture of closed die near net shape forged products, ranging in size from 5lbs to 1500lbs fully heat treated and machined to customer specifications.
Full P&L financial responsibility, accounting for $100mm to $150mm of total corporation revenue with strong EBITDA performance year over year.
Responsible for the day to day operations of 300 employees in the Forged Products Plant consisting of: Forging, Machining, Heat Treat, Quality, Planning, Supply chain, Engineering and Maintenance departments.
Installed robotic cell on 6k forging line, increasing productivity by 73%, saving the company $1,245,000 per year.
Implemented SMED, reducing change over time from 168 minutes to 45 minutes.
Installed CNC machining equipment, reducing cost by 60% and increased productivity by %110, saving the company over $400,000 per year.
Converted heat treat line from Radiant to Direct fire resulting in a reduced operating cost of 40%, and increased throughput of 38%.
Established daily reviews with direct reports of internal financial, production, quality, and safety performance, using data driven metrics to drive improvements.
Implemented work order reporting to track productivity, set up time improvement, down time reduction, and actual to standard performance evaluation. Implemented Cost per ESH Metrics across all operations, driving productivity and cost improvements.
Implemented tool staging areas, tools boards and visual work instruction / job notification tables. Also implemented Kaizen, 5S, Tool Box Talks and daily housekeeping to improve employee productivity and retention.
Launched Kanban system which resulted in increased inventory turns from 4 to 20 over the course of 7 years in the forging operation.
Implemented monthly Safety Training program, which contributed to the plant setting new records for days without a loss time accident.
Led operational transition from commodity forging to more complex forgings for the Automotive, Transportation, Oil and Gas, and Aerospace Industries.
Interstate SW/Citation Corp
Navasota, TX 2003 – 2005
Managed over 130 employees simultaneously, in the machine shop, automotive finishing, primary finishing, and shipping/receiving departments.
Responsible for the daily operations, reporting and management of the Finishing department which handled all of the final processing requirements for each customer including shot blast / peen, coating, de-burr, serialization, mag particle inspection, painting, packaging, etc. Automotive line which performed similar functions but on a smaller scale directed at a few select automotive customers. Machine Shop which consisted of several CNC lathes and mills, manual engine lathes, surface grinders, and welding equipment. Shipping and receiving docks which handled all of the daily requirements of shipping and receiving for the company.
Evaluated and improved dozens of procedures and processes – leading to increased production by 39%, decreased labor by 16% with an overall sales-dollar to man-hour increase of 58% over the first 12-month period.
Improved many processes with safety and quality in mind, to benefit the employees as well as the company.
Left the company to pursue management experience in the forging operations.
CERTIFICATIONS / TRAINING:
Demand Driven Performance: (Drum Beat Rope Certified Trainer (TOC)),
Productivity Inc: Certified II Lean Eng. (Total Equipment Reliability, Kaizen / 5S in the workplace, TPM),
JCIT International: (Demand Flow Technologies Mixed Model Lean II, Demand Flow Technologies
Level Load and Kanban, Learning to See: Certified Instructor (Shingo Award) (Creating Continuous Flow, Process and Value Stream Mapping)
Five Pillars of Success: Certified Instructor (5S implementation)
Safety First / Dupont Stop
ISO 9000 / 14001