Daryl L. Mayes

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

Ringgold, Georgia 30736

423-***-**** (Cell)

adwfho@r.postjobfree.com

EXPERIENCE:

Phenix Flooring, Dalton, Georgia

Industrial Engineer (2014 – Current)

Acting Purchasing Manager: Procure raw materials for production area. Create purchase orders for Supplies include yarn, backing, plant supplies, office supplies and manage supply room. Create requisitions for parts, plant and office supplies and raw materials using ERP. Generate purchase orders and communicate with vendors to balance inventory while meeting production needs. Ensure proper inventory of raw materials in ERP system.

Manage standard product cost in ERP system. Provide standard cost of products, new product cost calculations, keep standard cost database current, maintain cost files for BOM, provide cost analysis for sales, development/analyze cost scenarios using excel and develop annual manufacturing production budget.

Create and present data analysis for weekly production team review using excel, PowerPoint and metabase dashboard.

Implemented metabase for charting and dashboards. Use metabase with sequel for data mining developing dashboards for management and associates.

Mohawk Industries, Dalton, Georgia

PROCESS ENGINEER (2012 – 2014)

Lead six sigma project activities to identify process improvements in extrusion plants. This included reduction of fiber waste and machine downtime by changing the process settings, training, maintenance, and upgrading equipment.

Use AS400 system for data tracking of breaks, color changes, pack life, waste, and analysis in extrusion to achieve maximum efficiency. Use SQL to retrieve data for analysis. Weekly updates of extrusion equipment yields, color changes, uptimes, pack changes and overall equipment effectiveness.

Manage the yarn inventory file (Quarterback) to assure any yarn that is not first quality is processed timely. Track the age of yarn in inventory to assure processed and keep from becoming aged. Download weekly file for analysis, checking for age of yarn, what needs to be reclaimed, or sold and send file to machine schedulers/planning groups.

Use JD Edwards Plant maintenance to maintain preventive maintenance schedules and inputs for plant

equipment.

Beaulieu Group, Dalton, Georgia

SENIOR INDUSTRIAL ENGINEER (2005 – 2011)

Identify process improvement projects and cost savings opportunities at the distribution center location. Provide project leadership and facilitate Kaizens on numerous cost savings teams including: installing scanner system and RFID on conveyor system, tube wrap consolidation, change product flow through warehouse, install new dock plates, dock doors, jumbo rolls project, replace heaters in building one, implement cross docking, UPS and sample rolls consolidation, runners and anti fatigue rolls, etc. Conduct analysis of warehouse to achieve productivity increases including specification for a Warehouse Management System (WMS) and Transportation Management System TMS).

Track, modify, and update engineered standards including packaging materials and labor standards in cost system.

Provide engineering support for the distribution plant manager and trucking manager and his staff. Data retrieval from the AS400 system for tracking and standardizing of trucking and outside warehousing. Locating, analyzing special equipment needs and track testing of equipment or programs. Recommend capital expenditures, process improvement changes, and plant yearly budget development and Capital request package. Perform economic justification and analysis to calculate Return on Investment (ROI).

Facilitator for the BLAST (Beaulieu Leadership and Success Training) training classes. Leading and teaching on the High Performance Work Place. Facilitate two modules in BLAST. Continuous Improvement and High Expectations. Facilitate the Flying Starship module for BLAST. Provide leadership to process improvement teams and implement the BLAST principles across management and hourly employees.

Training in Green Belt and lead the plant in Lean Manufacturing and Six Sigma techniques.

UCAR Carbon Company, Columbia, Tennessee

PROCESS MANAGER RAW MATERIALS (2003 – 2005)

Manager of the raw materials team to coordinate, and track the receiving and usage of raw materials for plant site. This involves communication with different department managers on materials needs and timing of delivery of materials. Communicating and tracking the delivery (truck, rail car, etc…) of materials from vendors to plant.

Manage and directed the Preventive Maintenance program, developing process improvement teams and setting direction for the teams. Maintaining / updating daily list of items that need P.M. and history list. Checking critical equipment items like pressure vessels, electrical breakers, building cranes, etc… and maintain correct license. Tracking of needed repairs, order parts, overtime list, and track work being completed by 13 mechanical and 14 electrical craftsmen.

Projects to identify cost savings and improvement ideas. Upgrade electrical system on building crane. Apply new material to furnaces walls to reduce labor and cost of brick replacement. Move grinding room to use labor more efficiency. Upgrade and repair equipment (lathe, gray planner). Lead project activities for other process managers (repair building roof, ergonomic counterbalance).

Member of the plant management team and facilitate the reviews of safety items, accident investigations, update safety manual, update standard job procedures, manage proper training, license etc… for the plant.

Input requisitions and track purchase orders in J.D. Edwards One World system

INDUSTRIAL ENGINEERING CONSULTANT (2002 – 2003)

Tiffin Motorhomes, Red Bay, Alabama

Analyze full body paint operation (develop cost tracking program) and identify continuous improvement projects. Reduce labor cost by 5.5%, and installed a waste recycle system. Reduced the overtime process/cycle time by 25% while increasing/raising the quality standard. Provide engineering support to manufacturing floor. Selected plant preventive maintenance program, implement, and train plant personal.

Mark IV Automotive, Lexington, Tennessee

Develop labor standards and modernize the manufacturing cost estimating program system for an automotive parts manufacturer.

Jones New York, Lawrenceburg, Tennessee

INDUSTRIAL ENGINEER (2000 – 2002)

Provide management and engineering support to operations in the implementation of PkMS (Pick Ticket Management System) project to eliminate paperwork, annual inventory, and more accurate tracking of inventory. Led, set direction and train operations in the use of this system. Used work process improvement techniques to identify areas of improvements and measured performance.

Develop, implement, and maintain hourly incentive pay program. Maintained standards database, measuring performance, training employees in cycle time reduction and setting direction for operations, develop and maintain operations layouts workflow information.

Train and mentor new less experience engineers.

E. I. du Pont de Nemours & Company, Chattanooga, Tennessee

INDUSTRIAL ENGINEER (1989 - 1999)

NORTH AMERICA APPAREL MASTER PLANNER (1998 - 1999)

Coordinate monthly long-range Sales & Operations Plan (S&OP) and asset utilization for North America Apparel Business, maximizing profits, and utilization of machinery and equipment and significantly reducing machinery downtime. Led and set directions for the business teams on long range supply vs. demand, resulting in lower inventory on a continuous basis.

Key member of the North America Apparel business planning team, regional segment teams, and the global planning process. Key user of Business Resources Planning (BRP) and S&OP toolkit (MIMI (ERP), Manugistics, S&OP database, etc).

Leader for the preparation and execution of the monthly S&OP process, including planning process, database preservation and data flow stewardship, monthly Master Planning Core Team (MPCT), S&OP, Profit Objective (PO) planning, global integration and five year planning for Apparel.

MECHANICAL MAINTENANCE ENGINEER/MANAGER OF MELT POLYMER AREA (1998-1999)

Provided direct supervision to multi-skilled mechanics in the daily operation of melt polymer area. These duties included Project Management, Design, Predictive Maintenance (TPM), Equipment Overhauls, etc.

PLANT INDUSTRIAL ENGINEER (1989-1998)

Used World Class Manufacturing/Lean techniques to analyze operations and identified continuous improvement projects. Developed and Utilized Activity Based Costing (ABC), training of plant personnel, maintained database and supplied cost data to operations. Assisted in the development and transfer of information to the SAP model.

Plant space coordinator, equipment, essential materials and supplies layout. Rerouted finish product flow, packaging materials and finish product storage. Designed and implemented space requirements/layouts, materials flow and technical support to manufacturing, resulting in multiple areas of profit, including $220,000 based on better distribution center utilization.

Interfaced with customers and vendors to assist with bar coding problems, labels, selection, and testing of equipment and design of new packaging supplies.

Designed, team leader, financial management, functional description, and layout and construction implication of an automated robot yarn packaging project. This project consisted of automated robot-packaging facility to process tubes of yarn onto pallets. This resulted in 50% reduction of packaging time and labor costs along with significant reduction in customer complaints.

Performed several hundred economic evaluations, cost studies and labor requirements for new areas. Ranging in size from $25,000 to $30 million justifying spending dollars on potential programs. This included modeling the program in a computer format and converting all project premises or assumptions to dollars saved or dollars spent. Economics calculations included Internal Rate of Return, Net Present Value, and Payback.

Member of Program and Cycle-Time Excellence (PACE) project teams. Served as the Financial Analyst for the teams and as a consultant to manufacturing.

Performed Cost Decision and Risk Analysis, developing alternative recommendations.

Project lead responsibilities included layout design, material flows, conveyor equipment, and other mechanical equipment. Following construction projects, final equipment inspection and checkout, start-up of equipment, training plant personnel on new equipment and turnover of equipment to manufacturing area. Developed labor requirements and package/case components to be used.

Maytag Company, Admiral Division, Galesburg, Illinois

INDUSTRIAL ENGINEER (1989)

Designed layouts, new tooling and conducted time studies and set rate standards.

EDUCATION

Completed some Post-Graduate work in Industrial Engineering, University of Tennessee at Chattanooga, Tennessee and University of Tennessee at Knoxville, Tennessee

B. S. in Industrial Engineering, University of Tennessee at Knoxville, Tennessee, March 1988

ADDITIONAL AREAS OF ACADEMIC COMPETENCE

Other computer training included InfinityQS, Microsoft Access Database, A+ Certification, HTML, AutoCAD, Fortran, Basic, DBASE, GPSS Simulation, Pro-Model, Microsoft Excel, Microsoft Word, Microsoft Outlook, Lotus, 2020, Lotus Notes, SAP, sequel, etc.

MIMI Business Resources Planning and Sales and Operation Planning Principles, Time Study, Methods-Time Measurement (MTM), World Class Manufacturing, Green Belt and Lean Manufacturing. ISO 9000, Qualpro (Statistical Quality Improvement Techniques for Manufacturing Processes), Leadership Training, Decision and Risk Analysis, Truck Driver (tractor trailer), Diesel Mechanic, Real Estate Affiliate Broker

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