Maintenance Manager Plant

David M. Blackburn

Findlay, Ohio

************@*****.***

SUMMARY

I have over 25 years’ experience as Maintenance manager with extensive experience in plastics, food packaging, automotive, distribution and lean manufacturing with Six Sigma implementation in multiple production environments. I am a change agent who strives to bring about breakthrough improvements in an effective time. Adept at recognizing root cause problems solving and instituting preventive actions while developing high performing work teams.

EXPERTISE

Team Leadership; Manufacturing Optimization; Lean & Six Sigma Strategy Development; Large Project Maintenance; Micro-Main CMMS system Proficient; MP2 Data Stream CMMS System proficient; 5S and 6S proficient; Injection molding proficient; PET Stretch Blow; Electrical Troubleshooting; High speed packaging; SAP Software proficient; High speed labeling equipment; Allen Bradley P.L.C logic familiarization and HMI controlling system; Some Siemens PLC knowledge; Food industry AIB proficient; FDA compliance proficient; HVAC certified; OSHA regulations proficient in facility maintenance arena.

MAJOR ACCOMPLISHMENTS

Launched a retrofit upgrade from a Moog PLC controlling system, to Siemen’s controller in 4 days on a Liberty blow molding machine, and reduced budget cost by 35% and producing product the same day for1st article approval.

Lead a logistics crew of 26 technicians per shift and had rebuilt a state-of-the-art RS-200 sortation system from 1.2 M budget to a total cost of 225 K for all cost of parts, labor, and installation, to beat a budgeted record by 975 K.

Rebuilt a CMMS system by Micro-Main to affect new daily, weekly, and monthly Tasks to perform to a 95% OEE over the course of 4 months, and re-designed parts room and inventory levels to effect only needed parts for a certain parts average usage history through the CMMS system.

Spearheaded several new lines of blow molding equipment and installation, to accommodate new customer business requirements, ahead of budgeted schedule, by reducing project cost, outside contractor time, and internal man hours to beat the installation schedule and budgeted cost.

Trained several technicians in different industries on how to properly operate equipment by alternating schedules to provide personal hands-on training, by challenging them to become more proficient for the company and reduce workload in the maintenance departments by setting goals for each of the technicians and equipment operators.

Worked with a team of lean manufacturing professionals to reduce OEE, improve Quality, Delivery, so that significant shared savings were delivered both to the OEM and into the P&L of the company.

PROFESSIONAL EXPERIENCE:

High level of proficiency and working knowledge of hydraulic, pneumatic, and electrical systems

Proficiency in managing capital appropriation requests and project management

Strong root cause analysis and remediation

Solid understanding and demonstration of troubleshooting skills and best practices

AutoCAD

Preventative maintenance program software

11/22/2020 to present Contractor for Teijin Automotive North Baltimore, Ohio

Control budgets for capital improvements, programming a CMMS platform and have a total of 8 direct reports and working towards better OEE on existing equipment through process development skill I have learned

11/2020 to 11/2022 Owned personal Business in home improvement: Dave’s Helping Handyman Service

03/12/2019 to 11/2020: Process engineer (SME) B. Braun Pharmaceutical Devices

Working as a contractor for BBraun to identify any root causes that are big impacts for production losses and asses their current process for opportunities for improvements to also help them understand how to possibly increase production quantities. Generating standard work directions for training. Controlling maintenance reliability and OEE.

12/17 to 04/19 Maintenance Manager / Process Engineer, Amcor Rigid Packaging, St. Louis MO

Maintenance Manager of facility extrusion blow, Injection, injection stretch blow and wheel blow molding.

Responsible for repair and development of 19 production lines consisting of extrusion blow molding equipment, support equipment and automation, including, but not limited to robots and automatic packaging automation.

Leadership of 22 direct reports, engineering staff including processing of 19 various blow molding processes and packaging equipment.

Project manager of 14 existing legacy lines of production equipment to the installation of 19 total production lines using outside contractors and

Plant energy reduction champion for high and low air pressure air and variable frequency drives to reduce overall KW costs.

Manage the day-to-day CMMS maintenance SAP systems to achieve predictive maintenance through history and equipment costs.

06/13 to 12/2017 Owner of contracting business installing new PET, Rotary wheel, extrusion blow molding equipment and injection.

Setting up new Maximo CMMS systems, SAP CMMS systems for new customers, after new equipment installations and product validations are completed, also working as an outside contracted facilities project manager for UTC Aerospace Division, Troy Ohio, and for General Motors Springfield Oh truck manufacturing plant for the new GMC Sierra PU truck line 2018 a new addition to the existing Navistar facility, including paint, assembly, and cab assembly lines using union and non-union trades personnel to aid me in projects completions. Worked well with every employer and fit in culturally as a manager and processing engineer for the plastic industries that I had the pleasure of being around in my past years of management.

03/09 to 6/13, Maintenance Manager, Process Eng. Ring Container Technologies, Sidney, OH

Maintenance Manager of facility equipment (extrusion blow molded) facility, and line modifications. TPM & Focused Improvement Leader.

Responsible for TPM development and culture change. Provided vision and leadership to transform a reactionary mindset into a pro-active maintenance organization by extensive training and development of technicians.

Launched and implemented the new Micro-Main CMMS system tasks for TPM controlling equipment downtime mean between failures, using a Bar-coding technology for each piece of capital equipment and parts structure for history and cost analysis in preparing a monthly budget for the facility.

Developed the maintenance portion of a five-year strategic plan to make revolutionary change in the plant’s performance and best practices internally in the production lines.

06/05 – 1/08, Maintenance Manager, Process SME, Crystal Geyser, Moultonborough, NH

Re-designed the plant for Lean Operations for a 3-line pet Stretch Blow, Fill and labeling lines.

Eliminated indirect labor by over 6 personnel and improved quality metrics by driving correction back into the production processes to add the overall profits back into the facility.

Trained technicians on PET material, stretch blow processing, high speed labeling, and high-speed filling.

11/00 – 5/05, Maintenance Manager, Lowes RDC Distribution Center, North Vernon, IN

Handled the rebuild of an older distribution warehouse with 26 non salaried personnel and developed new processes from the ground up using Lean Principles and Six Sigma Techniques.

Rebuilt a state-of-the-art Sorting conveying system with 12 technicians and went under budget by over 900K

Set up MP2 Data stream CMMS software to keep accurate tractability.

11/97 – 8/00, Maintenance Manager / Plant Manager, Royal Plastics, Kansas City, KS

Led team members to advance towards objectives in Lean Production practices.

Functioned as Maintenance manager for Kaizen events and implementing rapid improvement events.

Led skilled trades in the repair and maintenance of robotics, PLC, hydraulic and electrical switchgear applications.

01/92 – 9/97, Plant Manager/Planner of Maintenance, Process Engineer, Microdyne Plastics, Ontario, CA

Controlled company functions, new customer service as well product development, production scheduling, and shipping quality products in a profitable time, using S.P.C and T.Q.M techniques to insure total customer service on all products and delivery.

Developed new product tooling and designs, training process of product quality, and packaging needs.

Maintenance PM’s and predictive planning on the facilities plastic processing equipment, including purchasing of electrical, hydraulic components, automated take out equipment, conveyors, and air-drying/ compressing units.

Coached six salary direct reports, in addition to 20 hourly shift personnel up to and including corrective action.

1981 – 1984, United States Army

Army Fort Jackson South Carolina, 3 years of active military service, and 1-year Army reserves in San Bernardino CA.

Education and Certifications:

5 Years Mgr. Training (Lowe’s Companies Certified in Manufacturing team building and employee increasing skills)

Sierra High School, San Bernardino, CA, completed HSD in the US Military during service.

HVAC, EPA Certificate Universal Technician for all industrial refrigeration support equipment in plastics.

Certifications in S.P.C & T.Q.M.

Certified FDA & USDA maintenance practices and compliance throughout multiple rigid packaging processing platforms.

Michigan State University, Michigan. Certificate of FDA compliance on all food grade plastics, rigid containers, and non-rigid packaging for food grade, medical, and cosmetic container industries and pharmaceuticals.

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