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Quality Plant Manager

Location:
Edmond, OK, 73034
Posted:
December 29, 2020

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Resume:

John E. Callery

Edmond, Oklahoma *****

405-***-****

adi0nb@r.postjobfree.com

[Operations & Quality Professional]

Results-oriented executive with a solid background within various functional areas in manufacturing, both domestic and foreign plant locations. Expertise includes Manufacturing Management, Production, Engineering, Supplier Quality, and Quality Control. Proven track record and strengths in achieving bottom-line results for safety, quality, growth, people development, profitability and increased efficiency. A multi-disciplined, hands-on leader offering outstanding leadership qualities, training and expertise.

CORE COMPETENCIES

Toyota Production System - Lean Manufacturing implementation s Automotive Production - Press, Body, Paint, Assembly & Powertrain s SPC s TQM s Six Sigma s Red X s PFMEA s VSM s APQP s PPAP s Continuous Improvement

sJD Power s NCBS s Warranty Improvement s QS-9000 s ISO-9001 s TS-16949 s ISO-14001 s Materials Management s Multi-Site s Plant Start-Up s Program Launch s Hoshin/Business Plan Deployment, Target Development and Sufficiency Planning s P&L s Operations s Quality/Supplier Quality Management s Multi-lingual s Productivity/Process Improvement

PROFESSIONAL EXPERIENCE

JEC Lean Solutions – Lean/CI Consultant 2014 – Present

Edmond, OK

Private Consultant providing expertise in the areas of TPS/ LEAN/Continuous Improvement as well as Hoshin/ Business Plan Deployment, Problem Solving, PPS, 8D, Red X, TPM/Equipment Effectiveness/SMED, Process Improvement, Standardization, Gemba / Visual Management, 5S, People Development, overall Change Management and Transformation.

ATC Drivetrain 2012 - 2014

Oklahoma City, OK

ATC Drivetrain remanufacture automatic transmissions for brands including Ford, Honda, Chrysler, GM, and more

Plant Manager

Reported to the CEO with responsibility for manufacturing and overall P & L ($100M+)

Led (2) directors and (8) managers across two sites for transmission and engine production with over 700 indirect employees.

Managed Engineering, Maintenance, Operations and Safety.

Established Hoshin planning and performance measurement, overall EH & S program, Gemba / visual management, VSM activity and overall Lean transformation.

Established and led cross-functional teams to drive improved performance across all value streams.

All KPIs and metrics were improved to levels never achieved in the company previously - SAFETY performance (60% improvement – TRIR, DAWC), HPU / Productivity (24% improvement), OTD (88% to 97%), FPY(from 80% to 93%), EBITDA (19% increase), SCRAP(21% decrease).

Generated substantial improvements in the areas of engagement, morale and employee satisfaction.

CHRYSLER LLC– ASIA PACIFIC 2008 - 2012

Shanghai, China

Manufacturing & Operations Leader – Asia.

Responsible for all manufacturing and quality operations within the Asia Region – vehicle production facilities in Beijing, Fuzhou and Taiwan.

Also led the JV projects between Chrysler and Chery Automotive and Great Wall Motors in Baoding, China. Included (6) export programs for Chrysler, as well as overall teaching, coaching and driving Mfg. and Quality system / process improvements along with lean manufacturing best practices.

Established new business plans and strategies with the Chrysler Asia President for other business cases and new joint ventures throughout the region.

Key member of the Strategic Council Committee (SCC) reporting directly to the Asia Pacific CEO.

Overall P&L responsibility.

GENERAL MOTORS CHINA – SHANGHAI GM 2005 – 2008

Shanghai, China

Leader – China Operations.

Responsible for all aspects of manufacturing, supplier performance and quality improvement activities across all SGM and GM China Operations, which covers (6) Vehicle Assembly Plants and (2) Powertrain Manufacturing Facilities.

Overall areas of authority and responsibility for driving improvement activities within the Manufacturing, Supplier Quality and Product Engineering (PATAC) organizations and ensuring that global processes were followed.

Led implementation and improvement of GMAP processes – In-Process / Delivery Quality, GVDP / GPDP, Product Launch, CPIP process, J.D. Power improvement planning, warranty and reliablity / durability improvement.

Responsible for driving GM Global and AP Regional quality processes and initiatives throughout the SGM and SGMW operations.

Reduced warranty cost by 19 million USD.

GENERAL MOTORS THAILAND LTD., 2000 – 2005

Rayong, Thailand

(New plant operation)

Director of Quality & Product Engineering.

Responsible for all aspects of Quality, including; Quality Engineering, Inspection Operations, Quality Assurance, Supplier Quality, Aftersales Quality and new program development.

Product Engineering responsibilities including New program validation, engineering changes / revisions, vehicle development process, vehicle and part validation and COP / type approval for all programs – Opel Zafira, Subaru Traviq, Alfa Romeo 156, Isuzu I-190, Chevrolet C-190 and GMDAT (Daewoo) J-200. Launched all programs to timing, cost and quality targets.

Led the development of Red X / Shainin Problem – Solving for the Asia Pacific Region and established a team of over 60 certified engineers over a 2 year timeframe.

Outperformed all product home plant locations in the area of quality and warranty performance.

Developed a stellar local national staff including a Sr. Director and Director which allowed for no additional expat leaders in this position when I moved to another role in GM.

SHANGHAI GENERAL MOTORS CORP.LTD, 1997-2000

Shanghai, China

(New Plant Operation)

Director of Operations.

Established the Quality Organization for the largest joint-venture company in China (GM and SAIC).

Responsible for all aspects of Quality, including; Quality Engineering, Quality Planning, Inspection Operations, Quality Assurance, Supplier Quality and Powertrain Operations.

Integral part of SGM becoming the premier operation within General Motors.

GENERAL MOTORS DE MEXICO, 1994-1997

Planta Silao, Mexico

Director of Operations

Ensured reliability and efficiency of new plant operations

Advised for the manufacturing areas of Press, Body, Paint and General Assembly.

Hired, trained and directed a staff of 20 direct reports.

Was responsible for establishing and Managing Inspection Operations, Supplier Quality, Quality Engineer and Quality Assurance sections.

Successfully drove the Silao operation to becoming the top GM truck production facility in quality and productivity

Implemented Lean MFG and build-in quality processes.

Lead the plant safety committee

Developed the SGM project into the most profitable division within GM.

Toyota Motor MFG., U.S.A Georgetown, Kentucky 1986-1994

Georgetown, Kentucky.

(New Plant Operation)

Assistant Manager of Quality Control

Managed quality operation and inspection for plastics, stamping, body and paint.

Oversaw assembly shops, product engineering, receiving/inspecting, raw material and audit lab areas.

Supervised and managed a staff of 288 personnel.

EDUCATION, TRAINING & PROFESSIONAL DEVELOPMENT

Bachelor of Science Degree - Chemical Engineering / Geology,

University of Kentucky

Lexington, Kentucky

MBA -American Graduate School of International Management

Business Leadership Program – Thunderbird Executive Education

General Motors University – Finance College

Risk Management

University of Michigan Business School Executive Education

Strategic Planning and Implementation

Center for Creative Leadership - Brussels Belgium

Leadership Your Perspective

MBTI, CLI, BENCHMARKS, behavioral assessments

General Motors University (RenCen campus and online courses)

Over 150 hours of various courses…Leadership, Problem-Solving, etc. 1994 – 2007

AWARDS

General Motors Chairman's Honor Award - High Quality Launch of the Suburban / Tahoe / Yukon GM Mexico 1995

General Motors Chairman's Honor Award - High Quality Launch of Buick W Program. Shanghai GM 1998

Thailand Prime Minister's Industrial Award - Best overall Quality System among all Thailand manufacturing companies - GM Thailand 2004

General Motors Chairman's Honor Award - Successful Development of Chevrolet Zafira for Thai Domestic Market. GM Thailand – 2003

J.D. Power Gold Plant Award and "Best in Class" IQS Gold Award for 1992 Camry (Launch Manager)

ORGANIZATIONS

American Society for Quality

Manager of Quality / Organizational Excellence Certifications – CMQ / OE

Society for Industry Leaders – Standard & Poor’s Vista Research

Industry Expert Consultant – Automotive Sector



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