Plant Manager Production Line

CHARLES E. SMITH

740-***-**** ******.***@*****.***

Manufacturing, production, and operations professional with success utilizing KPIs to monitor plant performance and drive continuous improvement to exceed business plan targets. Initiate plans and processes minimizing manufacturing costs through effective utilization of labor, equipment, materials, and capital. Model and implement quality improvement tools and concepts, including SMED, 5S, TPM, TPS, KAPS, and QBA. Turnaround performance champion, spearheading improvement of monthly revenue from $1 million loss to $400,000 profit. Documented success improving foundational inventory discipline and production flow to meet inventory accuracy and turnover requirements. Spearhead standardization and best practice implementations, achieving buy-in from production teams.

EXPERIENCE

AMERICAN Whistle COMPANY (AWC)

Plant Manager

Columbus, Ohio 02/2022 -Current

Oversee operation, including short and long-term production scheduling with simultaneous accountability for AWC manufacturing P&L . Oversee production group of 32 DL, and 3 support ID. Attended management meetings with the company ownership team to present KPI departures and review CI status, contributed to quality assurance meetings to review customer feedback. Reviewed staffing and budget along with long-term production goals.

Inspected production line and ensured productivity consistent with 5S and TPM compliance. Reviewed finished goods inventory and ensured load shipping readiness. Reviewed production trackers. Communicated shift priorities for the upcoming shift.

Developed scrap tracking system for plant that included process on floor and tracking database. Trained plant employees across all production lines and customers.

Playing integral role in company’s performance turnaround. Went from losing 50k a month to making 22k a month.

Contributed to maintenance and improvement programs. Improved quality audit scores.

Developed and installed an RFID tracking system for all materials and finished goods this included in bound raws and finished WIP and out bound shipments.

BOCCHI LABORATORIES

Senior Manager, Production Manager

New Albany, Ohio 05-2020 -08-2021

Oversee operation, including short and long-term production scheduling with simultaneous accountability for Bocchi manufacturing P&L. Oversee production group of 10 supervisors, 96 DL, and 3 support ID. Attended senior manager meetings to present KPI departures and review CI status, contributed to quality assurance meetings to review customer feedback. Reviewed staffing and budget along with long-term production goals.

Inspected production line and ensured productivity consistent with 5S and TPM compliance. Reviewed finished goods inventory and ensured load shipping readiness. Reviewed production tracker to set up changeovers and set shift production goals. Communicated shift priorities to incoming management. Traveled throughout other plant network to set up customer lines and revise legacy lines.

Developed scrap tracking system for plant that included process on floor and tracking database, eventually rolled across the Bocchi Laboratories. Trained plant employees across all production lines and customers.

Playing integral role in company’s performance turnaround.

Contributed to maintenance and improvement of FDA and FDA OTC programs. Improved quality audit scores.

KIRCHHOFF AUTOMOTIVE

Senior Manager, General Motors Production/Honda Production Special Project Manager

Waverly, Ohio 08-2016 – 12-2019

Set up new Kanban system that saved $7 million annually plant-wide by reducing downtime due to inefficiency of parts acquisition process.

Redesigned Accord production area to increase workflow and efficiency, leading to line being only line with capability of working 3 shift/5 days-per-week schedule, saving $650,000 per year by eliminating overtime labor hours.

Generated $259,000 per year in savings by redesigning and relocating sub-assembly area to improve JIT part scheduling, reducing transport time.

Oversaw operation, including short and long-term GM production scheduling with simultaneous accountability for Honda manufacturing P&L. Oversaw production group of 14 supervisors, 226 DL, and 8 support ID. Attended senior manager meetings to present KPI departures and review CI status, contributed to quality assurance meetings to review customer feedback. Reviewed staffing and budget along with long-term production goals.

Inspected production line and ensured productivity consistent with 5S and TPM compliance. Reviewed finished goods inventory and ensured load shipping readiness. Reviewed production tracker to set up changeovers and set shift production goals. Communicated shift priorities to incoming management. Traveled throughout other plant network to set up customer lines and revise legacy lines.

Developed scrap tracking system for plant that included process on floor and tracking database, eventually rolled out to KA production plans plants worldwide. Trained plant employees across all production lines and customers.

Played integral role in company’s performance turnaround, improving monthly revenue from $1 million loss to $400,000 gain at time of separation.

Contributed to maintenance and improvement of ISO 9001 program. Improved quality scores during tenure, resulting in site’s ability to bid new projects.

Oversaw overseas stamping production in Poland and weld operations in Germany, including logistics to get finished good to customer in SC.

Assisted in setting up new CCB line for MBUSA at Manchester, TN plant, which included line layout.

Served as production chair Honda Red Card Team, a cross-functional team with goal of improving Honda quality/production.

RIFFLE MACHINE WORKS

Second Shift Production Manager, Senior Management Group

Chillicothe, Ohio 05-2015 – 08-2016

Produces 86% of parts for world’s KW trucks and has 7 buildings (800,000 sq. ft.), with $140 million in annual sales and 836 employees.

Oversaw operations in manufacturing and warehousing campus for leading supplier of parts to PACCAR (Kenworth Truck). Resolved production issues and set goals for upcoming shifts; developed plans to meet customer JIT needs. Conducted shift handover meetings to assist with transitions between shifts. Investigated and documented wrong part in kit (WIK) and missing part in kit (MIK) issues. Updated production KPI for in-house use and reviewed finish goods inventory.

Created custom database to disseminate inventory information to senior management group and customer.

Developed cross-training program for all new and current employees.

Lead member of Lean Manufacturing team.

BUCKEYE DIAMOND LOGISTICS

Assistant Plant Manager, Kane Division

Columbus, Ohio 08-2014 – 05-2015

Leader in 3PL shipping services with 13 sites in OH, GA, KY, IN, and PA.

Managed material side of P&L. Scheduled production for Columbus plant; reviewed, responded and adjusted to KPIs, scheduling, production, and budget performance. Oversaw management staff during physical inventory. Generated PL, consumables, payroll, and quality reports. Oversaw hiring and training of new employees at all levels.

Generated savings of $331,000 per year by implementing training programs and systems that increased employee retention, which bolstered efficiency and quality.

Led plant to 41.3% production increase and $6,370 weekly operating profit. Increased employee retention.

EDUCATION

OHIO UNIVERSITY

B.S., BIOMEDICAL SCIENCES B.S., INDUSTRIAL ORGANIZATIONAL

Weld Inspection Certification / PPS / KAPS / SMED / TPS / SAP / WMS / ERP

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