Plant Manager Injection Molding

JOSEPH M. RICHEY ***********@*******.*** Bowling Green, Kentucky 270-***-****

DIRECTOR, GENERAL MANAGEMENT, PLANT MANAGEMENT

Results-driven and motivated with wide-ranging experience leading operations involving multiple plastics platforms. Great track record devising, evaluating, and implementing continuous process improvements to minimize waste and reduce costs. Establish effective safety and quality control programs, and encourage proactive participation across the manufacturing floor. Excellent communicator; success building cohesive teams focused on safety, quality, and production goals. Areas of expertise include…

Safety Culture Development Lean Manufacturing/Visual Factory

Team Building & Training Regulatory Compliance

Positive Change Agent P&L Accountability

Policy / Procedure Development Cost Reduction / Avoidance

GRAHAM PACKAGING 2018 - Present

Plant Manager – Multi-facility, Bowling Green, KY & North Kansas City, MO

Blowmolding, wheel & shuttle

EBITDA improvement: -$3MM 2018, +$3MM 2019, +$6MM 2020

$600k annual reduction in spoilage 2019 via raw material trigger limits

Leadership team rebuild, A3 problem solving process

Established structured 24-hour daily management system with visual factory tier process

Dupont STOP behavior-based safety program implemented

Layered audit program addressing safety, quality, standards, productivity

58% improvement in MOEE

33% reduction unscheduled downtime

AMARAY 2015 - 2018

Plant Manager – Elizabethtown, KY

High speed injection molding

P & L accountability

65MM annual sales, 48 lines: 180 – 600 ton injection press – 24/7 operation

High speed highly automated high volume media, medical and food packaging

Safety culture change, hazard recognition, BBS-behavior based safety

Rebuilt leadership team, instituted monthly town hall meetings

Implemented leadership and coaching process

Implemented Leader Standard Work for supervisors

Implemented A3 thinking problem solving

Implemented factory management tier 0, I, II, III system, Gemba walk

Implemented visual factory hour x hour boards, accountability boards

Commercialized 7 new production lines past 18 months

GRAHAM PACKAGING 2013 - 2015

Plant Manager – Belvidere, NJ

Blowmolding, stretch and extrusion

P & L accountability

20 lines: 12 stretch blow mold & 8 extrusion blow mold – 24/7 operation

Homecare & Personal Care Products - Union facility

Red plant designation – significant improvement needed in all areas

Implemented DuPont Safety STOP Program

Implemented SAP PM program

Business plan to refurbish worn blow molders & tooling

Hour x hour board, tier I, II, II visual factory implementation

MOEE improvement from 49% to 74%

Unscheduled down time reduced from 25% to 7%

AMCOR RIGID PLASTICS 2008 – 2013

Plant Manager – Franklin, IN

Injection molding & blowmolding

250MM annual sales

Recordable incident reduction to zero in 8 months. Implemented safety behavioral observation system

Implemented Safety Quality Assessment process – Gemba walk

Scrap reduction from 3% to 1.8% in blow molding, injection 2.5% to .8%

Plant labor alignment – reduction of workforce 20% (239 to 191)

Reduced outside warehouse square footage from 675,000 to 85,000

Reduced R&M monthly spending 30% (450K to 316K)

SAP implementation

P & L accountability

9 blow molder, 22 injection press blown bottle & injection preform facility – 24/7 operation

TEKTUBE GROUP, LLC 2005 – 2008

Vice President of Operations – Multi-facility, Las Vegas, NV - Croydon, PA

Profile extrusion, tubing

Multi plant responsibility ISO 9001:2000 certified PVC flexible hose and tubing operations

P & L accountability

24MM sales – 24/7 operation

Implemented safety program including fork truck certification

Developed internal financial reports for East plant, West plant, and SPA import business

Reduced labor costs by 25% through job/task balancing

$620,000 annual savings reducing vinyl scrap costs from 5% to 0.9%

Reduced factory costs to 1.8% sales from 3.8%

Reduced customer rejection rate to .02% of pounds sold

Standardized changeovers resulting in reduction of scrap costs

Established visual training/work instruction boards improving new employee training

Established visual quality master system resulting in consistency and uniformity of product

HUHTAMAKI AMERICAS 2004 – 2005

Molding & Thermoforming Manager - New Vienna, OH

Thin wall sheet extrusion & injection molding

Annual sales 65MM 2004 - 95MM 2005 w/commercialization of 3 major product lines late 2004

Facilitated plant safety committee

Implemented visual efficiency awareness and production/labor analysis system

Commercialized 2 & 4 cup & lid combo retail pack - 3 825 injection molding machines & semi-auto retail pack out

Commercialized 6 oz. cup & lid - 6 825 ton injection molding machines & CBW robotic handling systems

ALLEN EXTRUDERS 2001 – 2004

Production Manager – Holland, MI

Sheet extrusion

21 % improvement in production yield through focus on quick changeover, schedule optimization, and team building

Custom thermoplastic sheet extrusion - 5 extrusion lines; 60” – 110” bed width

Facilitated team successfully establishing visual standards library

BERRY PLASTICS 2000 – 2001

Assistant Plant Manager – Baltimore, MD

Injection molding

Plant Management Training Program - prep program for movement into Plant Managers position

Business analysis and plan to bring 100MM unit business in house from custom molder

Capital justification to automate 3 closure lining systems resulting in cost savings +100K annual

KSQ DIVISION WESTERN INDUSTRIES 1998 – 2000

Plant Manager – Multi-facility, Winfield, KS

Blowmolding, large part extrusion blow molding

Multi-plant - 18 Blow molding Machines - Annual sales 31MM

300 Employees 24/ 7 operation

14% increase in labor efficiency and 13% increase in schedule attainment after 120 days

Plant up time improvement from 50% to 80% after 180 days through schedule optimization

Reduced labor as a percent of sales from 26% to 17%

ARKAY PLASTICS 1998

Plant Manager – Arkay, AL

Injection molding

12 injection molding machines - annual sales 18MM

Tier 1 supplier to GM and Delphi Automotive supplying interior components for Mercedes Benz

Complete plant cleanup, organization, preparation for Delphi Automotive contract, and due diligence process

Achieved QS 9000 re-certification from ground zero

GEMTRON MOLDED PRODUCTS SYSTEMS 1992 – 1998

Manufacturing / Technical Manager – Vincennes, IN

Injection molding

Leader of Production, Assembly, Maintenance, Changeover, and Process Engineering teams

Accountable for safety, production, continuous improvement, & team development in union shop; 190 team members, 14 salaried

ISO 9002 Implementation team

Facilitated Production Optimization Team automating 16 injection molding machines resulting in a reduction of 32 operators

Developed Best in Class injection processes

Tested and implemented new resin resulting in material costs savings of $345,000 annually and a cycle reduction of 20 seconds

Implemented training program for process engineers - resulting in a standardized approach to processing

Trained supervisors, operators, and specialists during 16 injection molding machine / 72 mold startup

EDUCATION

Columbia Southern University

B.S. Business

ITT Technical Institute

A.S. Electrical Engineering

Vincennes University

TQM Principles of Management

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