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Plant Manager Pr

Cookeville, TN
June 01, 2022

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James T. Mansell

**** ***** **** 931-***-**** Cell

Cookeville, TN 38501 Email:


Plant Manager, Lean integrator, mentor, change agent, turn-around specialist, and hands on leader with diverse product, process, and industry experience.


Plant Manager, Cassemco, Inc., Cookeville, TN Jan. 2020 – present

Site Leader responsible for P&L, Operations, New Product Development, Manufacturing, Human Resources, Quality Assurance, Maintenance and Inventory Control, Purchasing, and Scheduling. Tasked as Plant Manager/Site Leader, responsible for turnaround financial management, plant layout rearrangement, Inventory Management Software replacement and improvement, instill fairness and consistency in human resource management, improve team building, instill staff development, improve product cost estimating, improve sales communications, implement technology improvements, ISO 9001: 2015 Quality Management System Certification maintenance, and maintenance of SHARP Safety Program Qualification. Cassemco is a Foam Fabricator of various PolyUrethane and PolyEthalyen Foams, servicing Medical, Automotive, Marine, Outdoor Power Equipment, Coin Mints, and custom packaging industries.

Plant Manager, The Peregrine Steel Company, Sparta, TN Dec. 2013 – Dec 2019

Site leader responsible for P&L, Operations, Sales, Manufacturing, Human Resources, and new business development of the Tennessee Operations. The facility is a commercial steel blanking house, processing steel coils and blanks into raw material cut to size sheets for manufacturing processors. Processing more than 1,000,000#/month, the facility is flexible for mix changes and rapid delivery. We implemented a computerized inventory control and reporting software, consistent employment practices, became a certified Drug Free workplace, implemented standardized work instructions, upgraded equipment and plant facilities, improved quality standards, and improved operator and supervision training, while increasing sales, and improving profitability.

Manufacturing Engineering Manager, Goodman Mfg., Dayton, TN Sept. 2011 – Jan 2013

Responsible for Engineering and Tool and Die Operations support for the 24/7 manufacturing facility in the HVAC industry, resulting in $3,000,000 annual labor savings in 2012. Supported cultural change and TPM. Supported Lean initiatives resulting in First Pass Yield improvements, TPM/OEE, Productivity/Efficiency improvements, machine utilization improvements, and Scrap reductions and reduced returns. ISO Certified.

President, COO, and Owner,, Cookeville, TN. April 2008 – Sept 2011

Company President, COO, and owner full time, for Contract Lean Site Assessments, lean transformation coaching, and short term Rapid Improvement Event (REI) manager with customer savings implemented in excess of $20,000,000 annually, with little or no capital investment. Businesses serviced include job shop low volume large scale products, industrial products, small high volume consumer products, and large high volume high mix manufacturers. Successfully coached companies for sustainable continuous improvement for team building, mentoring, financials, operations, logistics, quality, customer service, and community service without significant capital investment.

General Manager, D&D Enterprises, Inc. Cookeville, TN. Jan. 2006 – April 2008

Turnaround of a commercial contracting business. Relocated business operations, and trained one of his sons to run the business long term. Full P&L responsibility for overall business operations, including Operations Management, Finance, Sales, Customer Service, Quality, Engineering, Cost Estimating, Accounting, Inventory Control, Human Resources, and Field Operations. Metric goals achieved include:

-Successfully turned the business around for sustained profitability

-Relocated overall operations to support business growth needs, for approximately 35 employees

-Trained and mentored one of the owner’s son to run the business.

Director of Engineering and Maintenance, Nielsen Bainbridge, Gainesboro, TN Apr 2000–Nov. 2005

Nielsen Bainbridge, LLC is an international aluminum extrusion company with finishing, anodizing, paint, packaging, chop services, and distribution of picture frame products and private contract service extrusion products. Volume extruded totaled over 9 million pounds/yr. Implemented a new Custom Extrusion Business Unit in 2003.

-Responsible for Engineering and Maintenance team leadership to support three-shift aluminum 275,000 sq ft. 24 hour/day manufacturing operations (275 employees):

-Improved First Pass Yield 10%, resulting in more than $1,800,000 annual saving and developed a new business unit for EBIDA increase of more than $220,000 in first 7 months.

-Functioned as Product Manager & Technical Sales Repr., for new Business Unit (started 6/2003).

-Implemented Quality systems for ISO9002 and ISO14000 compliance.

-Worked with TOSHA for voluntary safety assessment for new operations safety review.

-Implemented TPM software for MRO stock, PM’s, Work Orders, and Purchase Requisitions.

Mfg. Engineering and Maintenance Manager July 1995 – April 2000

France - A Scott Fetzer Company, Fairview, TN manufactures core and coil high voltage transformers and electronic ignition products for neon signs, and oil and gas industries (100,000 sq ft,/225 employees).

-Championed Lean Manufacturing efforts and re-engineering of the manufacturing facility to reduce labor costs, improve quality, reduce inventories, and reduce manufacturing lead-times:

-Successfully developed multiphase facility rearrangements for value stream improvements, and successfully:

-Redesigned obsolete product and acquired UL and CSA approval and exceeded sales forecast for medium volume production.

-Obtained ISO9002 certification (registered August 1998). Reduced OSHA recordables 25%.

-Supported custom and lower volume specialty transformer production.

-Implemented SPC, Computerized Maintenance PM Program (DataStream MP2) (TPM/OEE)

Sr. Process Engineer, Program Manager July 1991 – July 1995

Robertshaw-Tennessee, Algood, TN Robertshaw-Tennessee manufactures OEM and aftermarket automotive thermostats and related emissions automotive products (90,000sq ft/150 employees).

-Sr. Process Engineer: I supported manufacturing operations of high volume automated production of automotive thermostats.

-Worked on EUL thermostat cross functional team (8 team members) as Program Manager to develop a new family of products and processes (OEM Tier 1 and 2, and aftermarket thermostats).

-Obtained Q1 and TS certifications for automotive thermostats.

-Selected, trained, and supervised the new EUL thermostat product operations for 6 months

Lean Champion/Sr. Process Engineer DeZurik, McMinnville, TN. Aug 1988- July 1991 DeZurik manufactures industrial valves and valve actuators. Responsible for development and implementation of short and long range Lean/JIT improvement plans. During the Gulf War period, we grew our business by having standard product work cells which allowed us to reduce the lead times from 11 weeks to 24 hours for domestic shipments and 36-48 hours for export shipments of standard gate valves. I also set up and managed the pneumatic actuator operation in 1990 – July 1991. I was recruited away to set up a plant in the Cookeville, TN area. (240,000 sq ft./300 employees).

Manufacturing Engineering Manager, JIT Champion Dec. 1987 – Aug 1988

Dennison-Carter’s, Inc., Crossville, TN, manufactures permanent markers and highlighters for consumer stationery product lines for wholesale and retail customers and distributors. Savings realized in excess of $700,000 annually (110,000 sq ft/150 employees).

-Very high volume automated production support in excess of 15,000,000 units annually.

-Championed JIT/Lean re-engineering efforts for the facility, resulting in 97% reduction in quality complaints by implementing SPC on ink filling operation at assembly, external PPM defect rate reductions from 180,000ppm to 450ppm, lead-time reductions from 3 weeks to 24 hours, Work In Process (WIP) inventory reductions of 60%, and Finished Goods Inventory reductions of 80%. Managed 5 direct Engineers and a clerk. Setup a PM program. The plant was scheduled to close when I started, and was still profitable and in Crossville 12 years after I left.


Bachelors of Science in Engineering (Industrial Technology) from Tennessee Technological University, Cookeville, TN. Minor: Business Administration.

Certificate of Completion: TTU Highlands Outstanding Local Leader Economic Development Seminar,

Red Cross First Aid first responder and AED fist responder.

Community involvement: Church Deacon, Chamber of Commerce Board of Directors, local Board of Education Business Leader Educational Speaker, TTU Manufacturing Engineering Technology Advisory Board, Tennessee Tech Engineering guest Speaker: Engineering 101. Director: White County Anti-Drug Coalition.

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