JAMES D HORN

*** *. ******** **.

Trafalgar, IN, 46181

Cell# 317-***-****

adyrpp@r.postjobfree.com

Summary

Experienced Plant Manager with a demonstrated history of working in the automotive industry. Skilled in QMS: ISO 14001, IATF16949/ISO9001. Hands on experience implementing Lean/TPS principles -5S, kaizen, one-piece flow, standardize work, and Kanban… Strong background in maintenance and manufacturing engineering. 20+ years of Injection molding experience.

Professional Experience

Heartland Automotive, Greencastle, IN Apr 2019 – Aug. 23

Plant Manger

Responsible for 350 employees 11 direct reports; 300k square feet Japanese facility; primary customer is Subaru (SIA & TAI), A three shift operation 5/24; four Assembly departments, Two Paint departments, Injection molding department, Vacuum molding department, Powder Slush molding department, a Headliner stamping department, Maintenance Department, Quality Department, and Kaizen Department.

Create a safety culture to insure a safe work environment.

Strictly managing the site costs, ensuring a variable cost culture by flexing monthly budgets in line with sales.

Managing and motivating staff, providing coaching and support to empower individuals to fulfil their potential while ensuring they make a significant contribution. Developed KPIs for staff members to drive continues improvement in all Departments.

Led team in delivering the following results:

oDeduced the DART rate and TRIR rate to below national average.

oReduced customer quality PPM from 313 to 89.

oImproved on-time delivery from 76% to 93%.

oSuccessfully reduced manhours, saving the company 2.2 million through efficiency gains,

by establishing lean manufacturing techniques and kaizen activities.

Flambeau, Columbus, IN Apr 2011 – Apr 2019

Plant Operation Manager Promoted 2016 –2019

Provide leadership for the successful day-to-day operation of the facility; Primary customer base 70% retail and packaging, 30% Automotive (Chrysler, IAC, and Faurecia), successful implemented ISO 14001, IATF 16949/ISO:9001, 2016.

P/L responsibility including the development and achievement of budgetary goals to ensure the long-term viability of the facility.

Responsible for 150 total employees; 177k square feet facility; Three shift operation; Assembly departments, Injection molding department, blow molding department, Quality department, Engineering department, Maintenance department, Shipping and receiving departments, and purchasing and scheduling departments.

Manage operation expenses and strive to be a low-cost producer.

Maintain and support a superior safety program.

Analyze workforce requirements.

Allocate human and equipment resources and direct production employees to attain all established goals.

Encourage and promote operating in a continuous improvement environment.

Maintain and develop customer relationships.

Verify compliance with all legal and company standards.

Participate in long-range plant expansion and equipment strategies.

Implement/Manage company’s SMED program.

Implement/Manage cost reduction program.

Manufacturing Engineer II promoted 2014 – 2016

Manage plant’s manufacturing engineer operation and personnel.

Implement company CI program.

Mechanical engineering functions

Implement new plant product launches.

Assist with tool program management.

Oversee cost reduction program.

Implement Engineering Change Requests, route sheets, and bills of material.

Capital equipment acquisition and project management.

Manufacturing Engineer I Promoted 2011 – 2014

Generate product cost estimates.

Assist implementation of new product launches in the plant.

Assist tool design engineer with tool design reviews.

Assist with cost reduction program.

General engineering functions for the plant.

Shift Manager 2011 – 2011

Manage 3rd shift injection and blow molding operation.

Manage shift personnel to meet the production schedule while maintaining safety and quality standards.

Enforce company standards and policies.

Use problem solving to make improvements in scrap, labor efficiency, and machine downtime.

Maintain employee-training records, update payroll, and conduct employee evaluation and reviews.

Home Design Products, Alexandria, IN Aug 2006- Feb 2011

Operations Manager

Manage the day-to-day operations of a 24/7 molding department.

Developed training program.

Implemented 5S and CI (kaizen) program.

Managed 4 salaried direct reports and 50 hourly associates.

Lead continuous improvement actions to improve production, machine OEE, and part quality.

Implemented problem solving techniques, which decreased scrap by 42% over five years.

Implemented 5S program, which improved the general safety of the production floor.

Despite extremely tight deadlines, met customer demands for 12 new product launches by managing personnel for the new assembly process, packaging, mold, and material changes.

Harman/becker, Martinsville, IN Sep 2004 – Jun 2006

Production Manager

Managed day-to-day operations with a primary customer base of Chrysler, Hyundai, Toyota, Mercedes, and BMW. Ensuring the successful operation of assembly, maintenance, and molding departments in a union environment.

Managed 11 salaried direct reports and 284 hourly employees.

Lead continuous improvement of quality and production through the implementation of kaizen activities, 5S, Kanban, and the Harman Production System (lean).

Reduced scrap by 64% using team problem solve activates.

Improved labor efficiency by 10% through implementation of standardized work practices.

Gecom crop, Greensburg, IN Sep 2000 – Sep 2004

Assembly Manager

Maintain the concept of QCDMS to meet Customer satisfaction standards with a customer base of Toyota, Lexus, Nissan, Mitsubishi, Suzuki, and GM.

Developed department policies and procedure for 3 salaried and 300 hourly employees.

Company’s representative for BAMA organization for Toyota suppliers. Working with the customer and 96 other suppliers to implement improvements to supplier base. Goal is improving quality and delivery to Toyota. Help train suppliers in TPS concepts.

Developed and Maintained department budget.

Managed a cross functional team for continuous improvement of quality and production through the implementation of Kaizen activities, 5S, Kanban, and TPS.

Managed the assembly department by developing a team approach to problem solving and training.

Implemented Kaizen Program. Saving 4,500 Sq. Ft., $250,000, and a labor avoidance of 27 employees.

Assistant Molding Manager

Managed the injection molding department and mold repair department, a 24/7, four shift operations with 33 horizontal machines and 7 vertical machines, 6 salaried and 78 hourly associates.

Developed and Maintained department budgets for both departments.

Improved scrap and production by implementing programs for Kaizen, 5S, Kanban, problem solving.

Valeo Sylvania, Seymour, IN Aug 1995 – Sep 2000

Sr. Production Supervisor

Responsible for overseeing the daily operation of a section of injection molding machines, sub-assembly, and assembly. Conducted monthly meetings with employees covering production targets and safety goals. Helped implement and monitor ISO 14001 and QS 9000 systems.

Primary customer base was, Chrysler, Ford, and GM

Worked as a part of a team to help set up the Kanban system.

Helped Implement 5S and One-piece flow.

Oversee the clean room for Bezel reflector coating.

Education/Training

Oakland City College, Oakland City, IN

B.S. Management of Human Resources

Indiana Vocational Technical College, Madison, IN

A.A.S. Electronics

Military Experience

Indiana Army National Guard – Retired, Rank – Major (resume available upon request)

Special Training

Valeo Production Systems (lean), Zenger Miller, Stress management, AMA Mgt. 1 & 2, QS 9000, HazMat, TPS, Honda’s 5P problem solving, SPC, and APQP, Team Problem Solving, ISO/TS 16949:2002, Supervising and Managing People, Scientific molding, Two 10-hour OSHA courses, Routsis training, TWI (training within industry) – employee relations and how to train, IATF16949 2015, ISO:2016, and ISO14001.

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