Douglas Andrew McCullough

* *********** *****

Greer, SC 29651

864-***-****

adr5py@r.postjobfree.com

PLASTIC OMNIUM, Anderson, SC Oct 2015 – May 2022

Shift Manager

Manage 30 employees which includes production, quality lab, maintenance technicians

Has the ability to drive and coach the workforce to meet and exceed production goals while keeping safety at the forefront. Also, understands and has the ability to administer discipline when necessary

Created an environment in which others are motivated to consistently perform at high levels

Successfully prepared the team to meet Run @ Rate for New Tank Production Line using KATA and PDCA

Developed Standard Work and trained Water Spider/Team Leaders for 4 production lines

The Setup reduction project on P558 Assembly with a baseline of 40 to 60 min C/O down to some changeovers are taking less than 3 mins

Monitor and controlled Direct/Indirect Labor cost

Monitor scrap using MRB process, RCCA,

Escalate issues appropriately when it comes to safety, quality and production

Ensure that CQA/ ISO/TS16949, and other regulatory requirements were met.

Made daily decisions regarding safety quality, productivity, and employee management

Coordinated all work assignments to associates, which included blow mold tool change, assembly set-ups, and production flow to support customer commits.

Facilitate and support Lean Manufacturing initiatives within the department

LEAR CORPORATION Duncan, SC May 2015 – Oct 2015

Continuous Improvement Manager

Handle in-house training on CI tools and methodologies and guide employees.

Reestablished 5S

Managed continuous improvement projects

PIERBURG INC. Fountain Inn, SC Oct 2010 – Sept 2014

Business Excellence Coordinator

Lean Expert

DFSS Green Belt Certified

Support, Train, Mentor and coach Leaders, Supervisors, team Leaders and Operators on Six Sigma and Lean manufacturing principles, processes, and tools.

Strong success record of working in a matrix environment with a focus on building relationships and driving continuous improvements.

Ran kaizen events, rapid problem solving exercises, and other learning events

Strong organizational skills with project planning program management expertise.

Strong capability to coach and mentor, including front line supervisors.

Drive standardization and consistency.

Facilitated several continuous improvement projects

Assessed, modified, and implemented new machine general build specification checklist that now incorporates, safety, ergonomics and lean manufacturing concepts into every new manufacturing cell and machine build.

Setup reduction on 3 automotive part assembly line resulted in a 70% reduction in average change over time

Reestablished 5S

Established a 5S baseline

Trained employees on 5S

5S scores improved 62%

A resource for Six Sigma and Lean Manufacturing

Standard Work Analysis resulted in reducing 3 production lines by 2 operators each

Increased capacity resulted in three new production lines

Mentored engineers on the Lean and Six Sigma methodologies

Mentored Greenbelt Candidates

Standard Work Analysis resulted in implementing the U-shape concept on six productions lines resulted in a 50% reduction in headcount while maintaining Takt.

Environmental Management System Coordinator

Ensure that the organization successfully maintains ISO14001:2004 Certification

Review the company's environmental goals

Analyze its environmental impacts and legal requirements

Set environmental objectives and targets to reduce environmental impacts and comply with legal requirements

Established programs to meet these objectives and targets

Monitor and measure progress in achieving the objectives

Ensure employees' environmental awareness and competence

Review progress of the EMS and making improvements

Evaluate and improve all chemicals and update SDS

HONEYWELL AEROSPACE, Greer, SC 2005–Sept 2010

Production Supervisor

Managed 35 to 45 employees in the Blade and Nozzle Cells and along with Airflow/Water Flow

Six Sigma Lean Expert

Six Sigma Plus Green Belt

Implemented HOS (Toyota Operating System concept)

Lean projects resulted in a $169,000 savings in operating costs and $350,000 cost savings in terms of inventory.

60% reduction in inventory

30% improved OTTR

Implemented SWIP that improved scheduled adherence by 27%

Facilitated a TPM event from which OEE increased from 30% to 61%. Maintenance down time decreased from 24.7 hrs. /wk. to 4.2 hrs. /wk.

Ensured that AS9100, NUCAP NADCAP, and regulatory requirements were met within the cells.

Monitored scrap via effective product flow, set-up reduction, lean manufacturing, RCCA, and the use of the Six Sigma tools.

Made daily decisions regarding safety quality, productivity, and employee management.

Coordinated all work assignments to associates which included machine set-ups and production flow to support customer commits.

Facilitated and supported Lean Manufacturing initiatives within the department

HONEYWELL AEROSPACE, Greer, SC 1996–Jan 2005

CNC Programmer/Set-up Technician/Operator

Six Sigma Plus Green Belt

Operated a variety of CNC grinding and milling machines

Set up and programmed edited on grinding, milling, and proving out programs using Allen Bradley, Fanuc,

Familiar with AS9100, NUCAP NADCAP, and regulatory requirements were met within the cells.

Participated in set-up reduction, lean manufacturing, RCCA, teams using Six Sigma tools.

Rated in the top 10 % during employee yearly evaluations

Certified Trainer; Trained operators on different on all both manual and CNC machines on all class levels

NATIONAL TOOL & MANUFACTURING CO., Greenville, SC 1988–1995

Machinist/ Mold Maker

Manufactured ejection mold sets by grinding, milling, and assembling the molds.

Set up and Operated Blanchard and Mattson grinding machines, and

Set up and operated CNC Makino horizontal milling machine.

MILITARY EXPERIENCE

UNITED STATES MARINE CORPS, Camp Lejeune, NC 1984-1988

SOUTH CAROLINA NATIONAL GUARD, Fountain Inn, SC 1991-1997

EDUCATION

MBA/Technology Management, University of Phoenix, Phoenix, AZ 2004-2006

BS Business / Major in Management, University of Phoenix, Phoenix, AZ 2001-2003

AS Business Management, Greenville Technical College, Greenville, SC 1997-2000

Mechanical Engineer 20 Hrs. Greenville Technical College, Greenville, SC 1996-1997

CERTIFICATIONS

Emergency Response Operations Level-24 HR HAZWOPER May 2014

Red Cross First/CPR/AED Instructor, Red Cross, Greenville, SC Jun 2012

Lean Master Pierburg Automotive, Fountain, SC Jan 2011

Six Sigma Lean Expert Certification, Honeywell Corporate Learning Center, Morristown, NJ Jan 2010 Six Sigma Green Belt Certification, Honeywell Aerospace, Greer, SC Jan 2001

Track Vehicle Repairman, United States Marine Corps, Aberdeen Maryland Proving Ground Jul 1944

Automotive Technology, Donaldson Career Center, Grenville, SC Jun 1983

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