Operations Manager

THOMAS R. FOSTER

*** ***** ** **** ** ***** *********@*****.*** Cell 803-***-****

PROFESSIONAL PROFILE

Highly effective Operations and Production Management Professional with extensive experience in paper converting, capital management, and managing continuous improvement efforts. Rapidly able to identify and correct process gaps to enhance performance and drive business excellence. Recognized for achieving quick positive results in difficult environments.

CORE COMPETENCIES

Continuous Improvement using Lean Tools, RCA, Waste Walks.

Capital Projects

White Belt Certification

New Equipment Startups

Skilled Communicator

Sense of Urgency

Assessing Training Needs

Developing Plans

Future Leaders Development

PROFESSIONAL WORK HISTORY

GEORGIA PACIFIC – Prosperity SC Dry End Supervisor

Current

Responsible for Safe and Efficient Operation of the Finishing Area of a Lumber Mill that produces approximately 150 million board feet per year. Responsible for scheduling of daily production, training, work assignment, crew selection, and motivating team to achieve optimal results.

FOOTPRINT – Richburg SC 2019-2020

Production Manager

Responsible for Safety, Quality, Cost, Productivity, and Availability for food and industrial packaging operation. Responsible for leadership staff of 12 and workforce of 160 employees. Footprint’s mission is to eliminate single use plastic by providing sustainable fiber-based alternatives. Facility utilized ten molded pulp formers to facilitate the manufacture of plant-based fiber packaging such as meat trays and bowls for retail distribution of meats and vegetables and packaged meals. Customers include Beyond Meat plant-based proteins and Conagra Heathy Choice brands.

INTERNATIONAL PAPER Prosperity SC 2015-2019

Operations and Maintenance Coordinator

Facility is an extrusion coating operation that adheres polyethylene to paperboard to provide moisture barriers for beverage and food packaging, primarily paper cups. Key customers include Coca Cola, McDonalds, Wendy’s, and Burger King. Responsible for Maintenance scheduling, maintenance spending budget, and availability. Worked with Production and Maintenance to set and schedule daily, weekly, and monthly maintenance priorities. Oversaw development and use of best practices and work systems. Led CI efforts for plant. Productivity increases of 12% and yield improvements of 4% realized. Functioned as Training lead and development of training systems.

INTERNATIONAL PAPER Campti LA 2013-2015

Process Manager

Lead Crew of 40+ Team members in Safety, Quality, and Efficient Operations on two paper machines, OCC recycling plant and respective shipping and warehousing areas. Ensure team is motivated and engaged. Operated at work class OEM.

INTERNATIONAL PAPER Crawfordsville IN 2012-2013 Converting Facilitator Corrugated Container

Guide safety, quality, and productivity for crew of 25 operating personnel.

Two, four color EVOL flexo gluers, one Martin three color flexo gluers, and one, four color rotary die cutters along with supporting equipment. Facility made packaging for beverage industry such as Anheuser Bush, Miller Coors, and major beverage distilleries. Customers included Coca Cola, Walmart, Amazon.

GEORGIA PACIFIC, Zachary, LA 1995-2001 & 2009-2011

Converting Manager (2010-2011)

Reported to Paper Operations Manager. Managed nine direct reports with 110 hourly employees for 1,500 tpd Cut Size (copy paper) converting operation, roll wrapping system and support equipment.

Improved productivity on sheeting equipment to the point of being able to shut one production line down and achieve needed productivity on remaining assets. Net savings of $3 million annually.

Reduced controllable overtime from 19% to 9% that save $120 thousand annually.

Production Leader / Gatekeeper Retail Converting Lines (2009- 2010)

Increased productivity by 150 tpd over previous year’s results on sheeters 4, 6 and 7.

Led Asset Strategy Improvement on sheeter 7. Yielded 320 improvement ideas all of which were implemented, improving productivity by 100tpd.

Production Leader Bath Tissue Lines (1998-1999) and (2010

Put in place OBC to improve operational uptime by 10%

Established use of Work Systems (Best Practices)

Led Asset Strategy Project to improve Maintenance and Operational uptime and reduce waste.

MEADWESTVACO, Covington VA 2008-2009

Finishing and Shipping Manager

Reported to Operations Manager. Managed seven direct reports with 70 hourly employees for Roll Handling Lines, Roll Wrapping Systems, Warehouse and Shipments. Position eliminated in restructuring.

Reduced external warehouse damage by $1 million.

Reduced inventory and lift truck expenses that saved $350,000 annually.

FINCH, PRUYN & CO,Glens Falls, NY 2004-2008

Division Manager – Converting (2006-2008)

Reported to Vice President Manufacturing. Managed 12 salaried employees with 100 hourlies for Mill Converting Operation and Offsite Contract Converting Operation.

Started up a used paper-to-paper Laminating System purchased from an idled plant, gaining ability to laminate most profitable grade in-house at a savings of $300,000+ per year.

Led development and implementation of systems that decreased change times which led to production increase of 25% by improving machine availability.

Focused on uptime and built infrastructure in off-site Converting Plant that increased productivity by 25%.

THE NEWARK GROUP, Franklin, OH 2001-2004

Manufacturer of recycled paperboard converted into corrugated and laminated products for industrial packaging and book covers.

General Manager (2001-2004)

Reported to Division President. Managed a staff of 10 salaried and workforce of 100 nonunion employees for Sales and Manufacturing, full P&L ($40 million) results, operations, and facility utilization.

Decreased production cost of paperboard by $70/ton, and plant waste by 33%. Increased Laminator productivity by 60%, and Corrugator productivity by 33%.

Reduced waste that allowed reduced purchased paperboard which saved $750,000 annually. Improved first year plant performance that resulted in nearly $1 million positive income variance.

GEORGIA PACIFIC, Zachary, LA

1995-2001 Converting Manager (1995-2001)

Reported to Fine Paper Operations Manager. Managed a department of 120 production workers and seven staff members for a 1,400/tpd operation converting paper rolls into cut-to-size paper for copiers.

Oversaw new equipment installations and existing equipment modifications that were completed on time and on budget.

Improved productivity by 15% on existing equipment, and reduced plant waste by 20%. Reduced quality complaints from 0.67 per 1,000 tons shipped to 0.12, a reduction of 75%.

Managed the successful upgrades of three production units and the addition of $5 million of new capital equipment. Set OEM world production records on #5 Cut size line twice.

Reduced OSHA Incident Rate from 9.5 to an average of less than 4.0 (during the last two years, the Rate was 2.7 and 0.0); achieved 400+ days without a Recordable Incident in 2000-2001.

Decreased union grievance activity from over 60 per year to less than five.

BOISE CASCADE CORPORATION - Boise Paper Solutions, International Falls, MN 1992-1995

Fine Paper Mill producing 1800/tpd of business papers.

Finishing and Shipping Manager (1992-1995)

Reported to Vice President of Operations. Supervised 200 hourly and 25 salaried staff. for an 1,100/tpd Fine Paper Converting operation, including Roll Wrap and Roll Handling System, Warehouse, Shipping Department, Outbound Freight Management, Mill Scheduling, and Customer Service.

Managed $28 million capital project to erect a dedicated building and install two 10-pocket ECH Will Cut-Size Sheeter that came in ahead of time and $2 million under bud

EDUCATION/TRAINING

Honorable Discharge USMC

Graduate and Graduate Assistant Dale Carnegie Effective Speaking and Communication Course Phillip Crosby Quality System, Crosby Associates

Supervisory Skills Workshop (Instructor), Champion Intl

Mutual Gains Bargaining, Getting to Yes

Pulp and Paper Short Course P.A.P.R.I.CAN Montreal QB

Market Based Management, three different Leadership courses with Georgia Pacific

Safety Leadership, Georgia Pacific, and International Paper

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