Shawn Warner

Huntsville, AL 256-***-**** ady6w4@r.postjobfree.com

Develops operations plans, improves delivery models, crystalizes strategic direction, and supports continuous improvements.

High impact leader with over 20 years of operational management experience, transforming inventive ideas to meet production scheduled, quality standards, and SQDCT targets.

Demonstrates a deep understanding of Production Management and Manufacturing Best Practices.

Guides strategic planning, designing, developing, and implementing innovative processes and system solutions through state-of-the-art methodologies, technology, training, and leadership.

Leads and motivates cross-functional teams to achieve positive outcomes and champions enterprise-wide change initiatives.

Cultivates an organizational culture of continuous process improvements, ensuring consistent alignment with corporate objectives.

Forges beneficial relationships with clients, vendors and suppliers, and internal and external business leaders across all organizational levels.

Strategic Planning Financial/P&L Management Testing & Evaluation Six Sigma & Lean Methodologies

Project Management Risk Management Continuous Improvements KPIs/Performance Management

IATF 16949 Management Manufacturing Process Change Management Production Scheduling

Regulatory Compliance Tactical Execution Decision Management Cross-Functional Team Leadership

Professional Experience

MATCOR-MATSU Huntsville, AL 2014 to Present

Automotive Stamping and Weld Assembly, Tier 1 Parts Manufacturer

Automotive Operations / Plant Production Manager (2019 to Present)

Direct daily Automotive Stamping and Assembly plant operations, ensuring optimal and efficient product flow in compliance with safety and quality guidelines and standards. Oversee 7 Managers and 350 employees across multiple shifts. Conduct Department Manager and Supervisor performance reviews. Develop and implement organization-wide quality, vision, strategy, policies, and procedures. Partner with leadership, operations, employees, and other functional areas, to promote a productive and amicable work environment and mentor others within the organization, ensuring consistent compliance with internal processes and procedures across the business.

Verifies and controls headcount for Assembly and Stamping departments, ensuring each department remained properly manned within budget constraints.

Test equipment for reliability and repeatability, ensuring achievement of cycle times versus volume needs.

Improved product delivery time by restructuring material flow from Stamping lines to Assembly lines by rezoning WIP warehouse layout and implementing WIP areas for larger production lines.

Lead daily Gemba walks with Department Managers and Supervisors to ensure compliance with quality standards and safety policies/guidelines.

Monitor SQDCT KPI tracking with Department Managers and Supervisors, ensuring attainment of projected goals within budget constraints and quality guidelines/standards.

Identified and corrected an ongoing issue of customers/OEMs not returning dunnage (requiring team to constantly repack product, costing company time, money, and quality concerns) by establishing an annual charge back for OEM customers that averaged $32K YoY for 5 years to date.

Developed a proprietary tracking sheet to collect data and calculated the time required to repack various products and tied cost of each team member involved in the process to quantify time/money loss.

Collaborate with Regional Manager and General Manager to support Department Managers with quality/materials/ maintenance to drive continuous plant quality, product flow, and efficiency improvements.

Forged relationships with major OEMs/customers and served as a primary contact in obtaining information and problem resolution.

Shawn Warner 256-***-**** ady6w4@r.postjobfree.com Page 2

(Automotive Operations / Plant Production Manager continued)

Leveraged extensive knowledge in Lean Manufacturing, and Six Sigma methodologies to maintain optimal operational performance.

Oversee all areas of staff management, including career counseling/career pathing/succession planning; hiring/termination/disciplinary action; and conflict resolution.

Worked with team responsible for rewriting Associate Handbook and decision management around enforcement of corporate/plant policies, safety rules, quality, Associate development, progressive corrective actions, attendance, dress code, Associate conduct/behavior.

Plan, budget, track plant capital projects.

Automotive Weld Assembly Department Manager (2014 to 2019)

Oversaw and coordinated daily operations, leading Tier 1 Automotive Assembly Production Department (4 Supervisors, 8 Team Leads, and 190-member team) throughout end-to-end processing of material and manufacturing products. Guided and directed strategic plans across multiple business functions. Developed and tracked product and project costs and timelines.

Implemented a manual efficiency capturing system, leading to OEE system utilization of ERP data, improving department-wide efficiency from 53% to 80% in under 18 months.

Utilized manual capturing system to effectively track all downtime issues identified by employee name, cell operation, and projected performance targets versus actual performance; then tracked efficiency per hour/per day over 1-month to compile measurable results/data.

Worked with IT to automate KPI tracking to maintain efficiency targets.

Automated system was rolled out to 2 other plants.

Designed a training system and accompanying documentation that covered each training process necessary to certify organization teams and customers.

Led regular department team meetings and participated in monthly plant presentations that involved KPI analysis/review.

Investigated all department near misses/accidents and submitted final investigation reports; completed 5s department audits and conducted plant-wide department audits as an active member of the Safety Team.

Collected, reviewed, analyzed KPIs for Safety/Quality/Efficiency/Scrap/Budget/Labor to meet/exceed customer expectations and organization goals.

Utilized 8D/5P/A3 methodologies to conduct root cause analyses in creating/implementing test effectiveness and reliability of counter measures while feeding forward findings to other applicable production lines as needed.

Oversaw new program launch, including ramp-up to start-up, creating new weld cells and fixtures; ensured reliability repeatability, obtainability of program volume needs, validation of poke yoke effectiveness, and compliance with quality standards for both plant and customers.

Collaborated interdepartmentally to review customer orders versus production scheduling, ensuring qualities, specifications, and specific products can be produced within designated timelines while maintaining compliance to company safety/quality/budget/ targets in a JIT manufacturing operation.

Secured IATF 16949 Internal Auditor certification and enforced department-wide compliance through proper training and ensuring all documentation remained up to date.

Reviewed production and operating reports and adjusted production scheduling for planned maintenance downtime for resolving equipment issues and preventive maintenance to minimize downtime on production lines.

Visited OEMs/customers regularly to troubleshoot plant product issues versus customer abilities of weld fixturing.

ISCO INDUSTRIES Huntsville, AL 2002 to 2014

Plastic Injection Mold Piping Products and Plastics Fabrication Manufacturer

Plant Manager (2008 to 2014)

Strategically guided and directed team of 150 (comprised of Shipping and Material Manager, Safety Manager, HR Manager, Engineering Manager, Maintenance Manager, Production Manager, and Fabrication Manager) across multiple phases in the production process. Identified performance gaps and inefficiencies to implement continuous process improvements that improved product quality. Managed plant-wide profit and loss accountability.

Designed a training system and accompanying training material that covered each training process necessary to certify organization teams and customers.

Successfully trained and certified approximately 150-200 participants nationwide.

Included a ‘high-end’ Train-the-Trainer certification.

Selected each year to lead the training process for internal teams and customers.

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(Plant Manager continued)

Oversaw all areas of staff management, including career counseling/career pathing/succession planning; hiring/termination/disciplinary action; and conflict resolution.

Maintained appropriate staffing levels (75% full-time and 25% temp) based on sales performance.

Analyzed equipment failures and deployed corrective repairs; reviewed proposals and hired contractors.

Reviewed plant requisitions, validated need and urgency, and granted approval based on plant/department budget.

Assessed annual tests to ensure plant complied with all city, state, OSHA safety regulations, noise and air quality standards.

Developed and implemented plant standard operating procedures.

Production / Fabrication Manager (2002 to 2007)

Propelled streamlined operational and organizational efficiency across Production and Fabrication departments to optimize workflow processes. Used Lean Manufacturing strategies to achieve business goals and revenue targets. Ensured adherence to production deadlines and budgets.

Maintained national inventory levels and placed supply orders as needed.

Negotiated competitive rates with vendors without sacrificing quality to meet projected deadlines.

Scheduled and prioritized jobs and projects to meet specified timelines.

Collaborated with Engineering Design and Planning Teams to identify/meet customer needs.

Organized production floor to optimize workflow efficiency for Team Members, driving high utilization of machines.

Processed payroll for Production and Fabrication jobs.

Collaborated cross-departmentally to ensure on-time completion of quality product.

Assigned job and reviewed blueprints / cad drawings were understood by fabricators and assisted them with any needs to complete the job on time.

Procured parts, supplies, tools, and equipment for Huntsville-based production and fabrication plant; documented items used for jobs at other plants.

Developed/implemented all department SOPs and Production Team training.

Identified and corrected issues with designs and drawings of jobs for Fabricators; worked with Corporate Design and Planning Teams on solving customer needs versus planned product.

Worked closely with Engineers on design and development of new water filtration systems product lines; conducted product testing to ensure quality standards.

Education & Credentials

Associate’s Degree in Business Management

Athens State University – Athens, AL

CERTIFICATIONS & TRAINING:

Six Sigma Green Belt Certification - Raytheon

IATF 16949 Internal Auditor - Sigma International

ISO 9001/14001 Training – Sigma International

Dale Carnegie & Franklin Covey Courses

CPR with AED Certified-Cintas

Lock Out / Tag Out Trained

ISCO Level 3 QA/QC Inspector - ISCO Ind.

McElroy Train the Trainer Certification - McElroy

TECHNICAL SKILLS: Microsoft Office Suite, Epicor ERP, Prelude ERP, Synerion Time and Attendance, ADP Time and Attendance

OPERATIONS MANAGER

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