Production Manager/Supervisor
Resume:
Douglas Andrew McCullough
Greer, SC 29651
********************@*****.***
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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