Production/Operations Manager
Resume:
Paul Whalen
Hopewell Junction, NY *****
***********@***.***
SUMMARY
Accomplished management professional with extensive experience in varied manufacturing/warehousing environments. Proven competence in leading diverse teams in dynamic work environments. Recognized ability to effectively communicate across all organizational levels. Notable capabilities include:
Project Management New Product Development Employee Motivation
Process Analysis/Improvement Quality Assurance LEAN Initiatives
Genpak LLC, Middletown New York 2017-2020
Production Manager
Managed all production operations of 200,000 sq. ft. SQF Certified styrofoam food container plant. Provided Production Planning for 24/7 manufacturing schedule. Refined material forecasting to improve preparedness for scheduling changes based on corporate demand. Worked with HR department on updating on-boarding procedures and policies for new hires. Responsible for 5 direct reports and 80 hourly union workers. Management Member of Safety Committee. Person in charge in absence of Plant Manager. Sole responsibility for hiring of Production Supervisors.
NOTED ACCOMPLISHMENTS
● Successfully lowered “per case” manufacturing cost to under $1.00 per case
● Developed new training procedures for improved retention of new hires
● Created inventory tracking system that increased monthly accuracy levels to an average of 98.5%
● Worked with corporate planning/forecasting on improving understanding of expectations/capabilities
● Represented Production in company wide 5S Program
CONTRACT POSITIONS: 2014-2017
Coventry Coatings Corporation, Newburgh, New York
Director of Operations
Contract position aimed at improving overall quality standards and on-time delivery performance. Liaison between Senior Management and Production Departments. Direct oversight in its entirety of company operations and plant functions. Provided leadership and direction to the manufacturing team in areas such as safety, planning, cost, efficiency, GMP’s, quality, and customer service. Managed the manufacturing scheduling process to meet customer expectations, by optimizing the use of plant resources to complete assigned tasks. Managed product run requirements to assure compliance to customer specifications. Optimized labor utilization to assure meeting or exceeding task expectations. Reviewed manufacturing and operating reports to resolve operational, manufacturing, and maintenance problems to ensure minimum cost and prevent operation delay. Monitored product yield material usage and material loss data. Maintained compliance with company policies, regulatory requirements, quality specifications, safety standards and sanitation practices. Coordinated maintenance schedule to control costs of manufacturing, quality, and sanitation. Monitored plant performance and developed/implemented action plans to understand and address areas of concern. Maintained continuous communication with all departments to assure manufacturing priorities and shortfalls are addressed in a timely manner. Embraced the role of Change Advocate and participated in continuous improvement initiatives.
ATI Flat Rolled Products, Waterbury, Connecticut
Operations Supervisor
Contract position through Technipower, (Roswell Ga.) for client Allegheny Technologies Incorporated, (Flat Rolled Products Division) in Waterbury Ct. Worked with management team during company “lock-out” of United Steel Workers union employees during labor negotiations of new contract. Provided oversight for production efforts of Industrial Strike Staffing Employees provided by Strom Engineering Corporation (Minnetonka, MN) in a cold-rolling stainless steel mill. Responsibilities included prep-line, rolling operations, annealing operations, leveling operations and Quality Assurance throughout all processes. Reported directly to Plant Operations Manager.
Schatz Bearing Corporation, Poughkeepsie, New York
Manufacturing Consultant
Contract position working with management team of an AS9100, ISO 9001:2008 certified specialty ball bearing manufacturer on evaluating employee performance in final assembly. Verified company SOP’s were being followed and counselled assemblers who were not in compliance. Improved communications with manufacturing to insure timely delivery of components to achieve targeted OTD’s. Reviewed scrap rates, conducted RCA’s and developed solutions. Refined metrics for employee performance evaluations.
Flagship Converters Inc., Danbury Connecticut
Operations Manager
Contract position directing all manufacturing operations of 91,000 sq. ft. metallized and color lacquered plastic film extruder/converter. Responsible for evaluating and renewing plant policies and procedures. Reviewed and updated SOP’s to improve material flow. Defined new QA requirements. Trained and directed supervisory staff on establishing and maintaining a positive factory environment. Developed and implemented program to monitor machine usage to evaluate preventative maintenance requirements. Coordinated and approved vacation requests to ensure continuous operations.
Brewster Plastics Inc., Patterson, New York 2010-2014
Production Manager
Managed all production operations of 90,000 sq. ft. ISO 9001:2008 Certified Plastic Injection Molding manufacturer. Provided Production Planning for 3 shift molding and assembly operations serving customers in the automotive, medical, pharmaceutical and food manufacturing industries. Developed and maintained Managed Inventory Systems based on customer demand. Reviewed new jobs for best allocation of resources and developed operating procedures for each. Designed New Hire Training Program consistent with ISO Training Matrix requirements. Implemented Cross Training program for existing employees. Responsible for 12 Internal ISO audits/Process Owner Reports annually. Worked with HR and QC managers on employee performance issues.
NOTED ACCOMPLISMENTS
● Developed and maintained Managed Inventory System to reduce inventory costs and product delivery times.
● Planned and implemented testing schedule for 30% demand increase of largest customer’s new acquisition.
● Rebalanced labor allocations between shifts to reduce set-up frequency and increase production capacity.
POP Displays, Yonkers, NewYork 2008-2009
Plant Manager
Managed the production/assembly/warehousing efforts of 435,000 sq. ft. plastic injection molding display manufacturer. Provided oversight for 175 union and non-union employees on 2nd shift of 24 hour manufacturing facility. Coordinated with 1st and 3rd shift Plant Managers in creation of production schedules, labor allocations and material requirements. Member of Implementation Team for LEAN Cellular Manufacturing model serving large scale customers including Walmart, Maybelline, Home Depot and Phillip Morris. Assigned and documented shop orders to First Line Leads and monitored progress to assure production goals. Reviewed SOP’s and presented recommendations for improved efficiencies to management. Collaborated with QC team to insure strict quality standards were maintained. Responsible for training of new employees. Conducted performance reviews and provided necessary counseling and training where indicated.
NOTED ACCOMPLISHMENTS
● Successfully identified, recruited and trained candidates for 2nd shift Leadership Team from existing employee roster.
● Led newly formed Team to develop new operating practices reducing “idle time” resulting in labor efficiency increase of 15%.
● Collaborated with Planning Department to increase on-time shop order completion to over 98%.
● Served on 16 member Facility Health and Safety Board.
The Mines Press, Cortlandt Manor, New York 2002-2008
Plant Manager
Managed the production, receiving/warehousing/shipping efforts of 110,000 sq. ft. printing plant. Planned schedules for 5 diverse departments with seven supervisors and 75 employees. Ensured operational efficiency and cost reduction through optimum utilization of resources and continual improvement of methods and procedures. Directed work priorities and timelines and adjusted resources to assure goals were met. Coached and mentored supervisors toward “Team Mentality” through direct reports and production meetings. Coordinated print production work and fulfillment schedules for vendor work. Conducted performance evaluations for production staff and set future performance goals. Worked with Operations and Finance Managers to develop annual budgets.
NOTED ACCOMPLISHMENTS
● Led the development and initiation of comprehensive preventative maintenance program resulting in 15% reduced downtime for major equipment.
● Designed and implemented “Discreet Issue” inventory system to monitor and eliminate sources of waste resulting in lower operating expenses and more accurate cycle counts.
● Planned production/proofing schedules for fifth division without additional staffing.
COMPUTER SKILLS
CRC, Intuitive, TMM, Epicor, Tandem/Walker MRP/WMS Systems, Oracle
RELAVANT COURSES
OSHA 10-hour General Industry Safety and Health 2018
Labor Arbitration Institute Conference on Labor Law and Labor Arbitration
NYC 2019
Contact this candidate