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Manager Plant

Youngstown, OH
December 23, 2020

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Matthew J. Futkos

Address: Phone:

**** *. ******** ****** * 330-***-****

Youngstown, Ohio 44511



Background includes extensive practical experience and education which have provided detailed working knowledge of these key areas:

Plant Management…. Engineering…. Maintenance….Quality Assurance

Tooling Design…. Six Sigma…. PLC Programming…. AutoCad…. Error Proofing Design

Excellent communication skills. Able to interact with all levels of management. Work well under pressure and against deadlines. Take charge of situations and deliver positive results.


11/16—Current Trivium Packaging (Exal), Youngstown, Ohio


Manage the engineering department, maintenance and purchasing department for this premium aluminum and steel packaging company. Company produces aerosol and general line packaging for pharmaceutical, food, beverage and general consumer goods. This includes custom manufacturing with advanced shaping, interior linings and lithography. Responsible for manufacturing facilities that include five plants totaling 1.7M square feet across North America, South America and Europe. Total engineering / technical direct reports 32. This includes multi discipline engineers and drafting, controls, electrical, robotic, and mechanical technicians. Member of Executive Leadership Team that set direction for the plants that includes budgeting and KPI goals for all 2.4k team members. Help drive these KPI’s to exceed goals, including safety ORIR, employee OHI, Scrap reduction, uptime, OTIF and OEE. Implemented a more robust engineering and maintenance team by creating cross functionality, apprenticeship program and driving preventative and predictive maintenance. Member of Food Safety Team and integral part of attaining FSSC 22000. Responsible for capital projects up to 12M USD. Responsibilities include new equipment procurement and installation, equipment electrical and mechanical upgrades, MES maintenance and ancillary equipment maintenance and upgrades. Worked closely with all team members through daily and weekly town hall meetings on resolving safety, equipment, training, tooling and suggestion needs. Improved standardized work with cross functional teams to optimize processes and reduce product variation.

04/14-10/16 Autoneum Corporation, Oregon, Ohio


Manage the engineering and maintenance departments for this Tier one automotive supplier. Company develops and manufactures acoustic and thermal management systems for automotive OEMs. These include components and modules for automotive interiors, engine bay encapsulation and underbody shielding. Manufacturing complex is comprised of four facilities totaling 440k square feet of active manufacturing space with 680 employees. Manage 24 direct reports, including design, process, launch, and controls engineers. Manage all plant capital projects including justification and capital request. Manage all new product/model launches from award of business to SOP. Responsibilities include commissioning of plant tooling and equipment prior to start up. Managed the development of an effective PM program using CMMS and maintenance KPI tracking to improve upon OEE and plant performance indicators. Serve as EH&S core team leader and management representative for ISO 14001. Also serve as core team member for TS16949 compliance for engineering, maintenance, facilities and EH&S. Manage resources for implementation of plant continuous improvement projects that positively impact plant safety, quality, customer delivery and manufacturing costs. Responsibilities also include maintaining building structures, grounds, utilities, fire suppression, boilers, chillers, high pressure intensifiers, air compressors, HVAC and ovens.

06/12-02/14 Heraeus Electro-Nite, Ellwood City, Pennsylvania


Manage this business unit for Heraeus Holdings LLC. Business unit produces sensing and measuring equipment for the steel and foundry industry. Business unit is comprised of 245 union employees within a 175,000 square foot manufacturing facility. Propose capital projects, assess staffing requirements and evaluate the monthly key performance indicators. Develop plans for efficient use of materials, equipment and human resources. Establish an effective inventory level of necessary raw materials. Maintain quality and environmental standards including ISO-9000, ISO-17025 and ISO-14001. Manage daily operations of the engineering and maintenance departments. Manage project teams and provide ongoing communication with external customers and suppliers. Supervise and coordinate the work activities of all assigned personnel in accordance with described procedures. Conduct annual performance reviews for direct reports and develop employee performance plans. Create, implement and conduct an effective mentoring program to development individuals within the facility. Manage company assets and procedures that are in accordance with company and industry standards. Established and maintained an effective maintenance program for all facility equipment and support systems. Operate this manufacturing facility in the safest, productive, cost effective and cleanest manner possible.

09/05-06/12 Automodular Assemblies, Lordstown, Ohio


Responsible for the quality, cost and delivery of this 100,000 sq. ft. automotive assembly facility with a workforce of 65+ UAW members. Supervise staff personnel, including managers, supervisors, electrical technicians, mechanical technicians and quality liaisons. Conduct monthly reviews with the Director of Operations that cover key areas, including P&L, goal attainment, cost reductions, variance analysis, and staffing. Participated in negotiation of the local union contract with the UAW. Create and enforce all plant policies and procedures. Ensure a productive, effective and safe work environment. Coordinate and drive continuous improvement of all processes to maintain competitiveness, reduce variance and manufacturing costs. Interface with all customers on product quality and service performance. Serve as Management Representative for ISO/TS 16949 certification audits. Support new and upcoming plant launches in all new locations.

05/04-09/05 Automodular Assemblies, Lordstown, Ohio


Responsible for the internal quality of manufacturing records, certifications and requirements of individual automotive customers. Developed work instructions, process flow diagrams, PFMEA’s, and controls plans for this manufacturing facility. Responsible for the implementation of the ISO/TS16949 quality standard. Raised quality rating with all customers through cross functional teams and “error proofing” implementation. Interfaced with customers to maintain positive customer relations and proactive problem resolution. Responsible for monthly quality reports to the corporate executive management team. Responsible for equipment design, error proofing and assembly processes.

05/01-05/04 Android Industries, Vienna, Ohio


Responsible for the design of process equipment and tooling at this automotive assembly operation. Managed daily operations of the engineering and maintenance departments resulting in process stability and reliability of process equipment. Developed and maintained plant processes through documented operating systems. Implemented a preventative and predictive maintenance program using CMMS / EAM software and through Total Productive Maintenance or TPM. Have extensive knowledge in the troubleshooting of electrical, mechanical, hydraulic, pneumatic systems, AC/DC drives, mechanical drives and conveying systems. Other responsibilities include, machine PLC programming, measurement system analysis, process and machine capability analysis, equipment calibration, preventative maintenance, plant safety, and continuous process improvements.

02/00 – 05/01 Lear Corporation, Lordstown, Ohio


Completed an intensive five-month training program in the discipline of Six Sigma at this Tier 1 automotive supplier. Have an in-depth understanding of Six Sigma philosophies, theories and application tactics. Able to apply the Six Sigma tools which include statistics, process control techniques, process diagnostic methods and experimental design. Utilized Six Sigma to form repeatable processes to solve critical manufacturing, engineering, and administrative problems. Mentored peers and middle management in the formulation and execution of these process improvement projects.

05/99 – 02/00 Lear Corporation, Lordstown, Ohio


Responsible for the daily operation of the maintenance department at this Tier 1 automotive supplier. Implemented a preventative and predictive maintenance program using CMMS software. Have reduced downtime and maintenance cost as well as increased reliability and repeatability of plant equipment. Supervised journeyman electricians and millwrights as well as production personnel at this unionized workplace. Able to troubleshoot PLC’s (A/B PLC-5, SLC 500 and Contrologix) using RSLogix software. Used ACAD and Autodesk Inventor to design tooling and fixtures for process and quality improvements. Have extensive knowledge of high-pressure steam systems, mechanical drives, vacuum systems and compressed air systems.

04/96 – 05/99 United States Can Company, Hubbard, Ohio


Responsible for the overall maintenance of this manufacturing facility. Supervised skilled union employees, which included journeyman machinist, electricians, and general maintenance personnel. Other responsibilities included the design of dies and machine parts, purchasing of shop equipment and materials, implementing a preventive maintenance program, and oversight of equipment overhauls. Sheet metal forming equipment and tooling includes deep draw (blanking, drawing, ironing, doming and necking). Other metal forming processes included punching, blanking, shearing, slitting, beading, seaming and roll forming.

10/91 – 04/96 United States Can Company, Hubbard, Ohio


Quality Technician, Pressroom Supervisor, Lithography Supervisor,

Assembly Supervisor and Shipping Supervisor.


04/04 Bachelors of Science Degree in Mechanical Engineering Technology


Willian Rayen School of Engineering and Technology

Youngstown, Ohio


Six Sigma Blackbelt

Mechanical Inspector

Quality Technician

Boiler Operator


Allen Bradley PLC’s and Panelview (HMI) programming using RSLogix 500, 5000 and RSLinx

Seimens PLC, and Drives, TIA Portal

Electrical and Mechanical design and troubleshooting

Pneumatic and hydraulics systems

AC/DC Drives and Motor Controls

MP2, Chase and Mainsaver (CMMS / EAM Software)

Total Productive Maintenance (TPM)

Minitab Statistical Software

Microsoft Project and Microsoft Office

AutoCAD and Autodesk Inventor (3D Modeling)

Stanley / Atlas Copco Torque Tool Programming

Resistance Welding Controls

Robotics Programming

Vision Systems Programming

Compressed Air / Vacuum Systems

Water processing / Carbon beds, Reverse Osmosis, and Deionization

High Pressure Steam Systems

ERP: SAP, Plex and M2M

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