Plant Manager Continuous Improvement
Resume:
Neal P. Lewis
Philadelphia Metropolitan Area
************@*****.***
https://www.linkedin.com/in/neallewis123/
Summary
Passionate and results-driven manager with over 25 years of experience in fabrication and plant operations. Proven expertise as an A-Team leader in diverse sectors including structural and miscellaneous steel, precision sheet metal, and industrial manufacturing. I am skilled at bridging the gap between senior leadership and the shop floor by respecting the human elements involved in the production process and empowering them to participate and improve operational excellence.
Experience
Hohmann & Barnard, Inc.
Continuous Improvement Leader 2023 – Present
• Directed lean implementation and led kaizen events across nine manufacturing and distribution facilities in the U.S. and Canada, improving process efficiency and standardization for a 300-employee organization with $56.1M annual revenue.
• Led SMED (Single-Minute Exchange of Dies) events, significantly reducing equipment changeover time, thereby increasing production time and reducing inventory.
• Championed Gemba walks as a tool for operational assessment, implementing Google Forms to streamline data collection for safety, production, housekeeping, and continuous improvement insights.
• Acted as a Subject Matter Expert (SME) for a $24M relocation of a legacy manufacturing plant to a new 95,000 sq. ft. facility in Ft. Worth, TX. Oversaw the relocation and logistics of key equipment, including CO2 lasers, CNC press brakes, hydraulic presses, coil feeders, and material automation systems, ensuring seamless setup and operational integration. Assistant Plant Manager 2022 – 2023
• Utilized Alere (MRP) and AccountMate (ERP) systems to manage production planning, inventory control, and financial reporting, ensuring seamless operations and data-driven decision-making.
• Analyzed operational metrics and established performance targets for key areas such as on-time delivery
(OTD), overall equipment effectiveness (OEE), and first pass yield (FPY) to achieve production goals.
• Developed and implemented manufacturing practices that prioritized quality and continuous improvement, driving operational excellence through LDM (Lean Daily Management) meetings and SQCDP (Safety, Quality, Cost, Delivery, People) boards.
• Established and enforced safety, security, and compliance protocols with regular inspections, audits, and DuPont Stop® training to achieve zero OSHA recordables or DART incidents under my supervision. Director of Strategy & Continuous Improvement
Off the Wall Company, LLC (OTW) 2021 – 2022
• Improved productivity and quality across multiple departments for a $12.4M company with 48 employees, specializing in design, manufacturing, and nationwide installation of retail environments.
• Analyzed and optimized processes in engineering, manufacturing, logistics, and installation, enhancing efficiency by aligning departmental goals and introducing real-time communication tools like employee apps for rapid problem-solving.
• Employed the Infor Visual ERP system to drive data-driven decision-making, enhance process efficiency, and support strategic initiatives.
2
Plant Manager
Kemper Equipment 2020 – 2021
• Led a team of 15-20 shop personnel at this $12.6M company specializing in custom quarry equipment design, new plant installations, and retrofits, including foremen, fabricators, welders, machine operators, painters, assemblers, and laborers.
• Enhanced project performance using Salesforce (CRM) by effectively planning and managing materials, inventory, and daily work schedules. Introduced one-piece flow and standardized work processes to optimize fabrication efficiency.
• Boosted shop productivity and quality through employee training, development, and standardized procedures that supported continuous improvement initiatives.
• Maintained a safe work environment with rigorous safety protocols and consistent equipment maintenance, achieving zero OSHA recordables or DART incidents under my supervision.
• Collaborated closely with sales, estimating, engineering, HR, and other departments to provide strategic recommendations and successfully execute capital improvement projects. Plant Manager
Falcon Industries, Inc. 2015 – 2019
• Headed plant operations at this $101.3M precision sheet metal company specializing in POP retail displays, consistently meeting monthly P&L targets through effective budget management, a strong focus on safety, and a commitment to high-quality production.
• Enhanced plant efficiency by establishing and monitoring key KPIs—such as On-Time Delivery (OTD), Throughput, and Customer Return Rate (CRR)—while conducting thorough budget analyses to identify and implement cost-saving opportunities.
• Drove continuous improvement by implementing Lean and 5S practices and equipping teams with problem-solving skills through targeted training.
• Leveraged Eagle ERP system to oversee production scheduling, inventory management, and KPI tracking, ensuring efficient plant operations and alignment with organizational goals. Project Manager
Capital Steel Service, LLC. 2013 – 2015
• A custom fabricator and steel service center generating $8.1M in annual revenue, where I collaborated closely with all departments—including estimating, engineering, production, and service—in this family- owned business.
• Collaborated with architects, engineers, and detailers to ensure the timely delivery of approval and shop drawings, maintaining project schedules.
• Coordinated with outside trades, subcontractors, and suppliers to ensure project alignment.
• Managed the change order (CO) process by overseeing pricing, issuing CO requests, and negotiating costs with general contractors, construction managers, and owners.
• Cultivated and maintained strong client relationships. Design Engineer
Amuneal Manufacturing Corp. 2010 – 2013
• A $25.5M architectural and design manufacturer with 100+ employees, where I contributed to the continuous improvement and optimization of engineering processes and controls.
• Work in partnership with sales to streamline the client review process and with project management to create innovative designs, developing solid models and shop drawings to produce custom store fixtures, architectural retrofits, and public art installations.
• Supported manufacturing operations by resolving fabrication issues promptly.
• Leveraged Sage ERP software to manage project workflows, track inventory, and streamline production processes, ensuring efficient coordination between design and manufacturing teams. 3
Assistant Shop Manager
The Rees Companies 2001 – 2010
• Oversaw and managed a team of welders, fabricators, and machinists, optimizing workflows and eliminating bottlenecks to ensure efficient task completion and increased output.
• Ensured all projects met or exceeded quality standards by conducting inspections and enforcing compliance with blueprints and specifications, while consistently meeting client deadlines.
• Managed inventory levels for materials and tools, coordinating orders to prevent delays, reduce material waste, and minimize downtime, ultimately improving profitability.
• Schedule and oversee routine maintenance of shop equipment to prevent downtime and extend equipment life.
• Cultivated a skilled and motivated workforce through effective leadership, ongoing training initiatives, and prompt, fair resolution of employee issues.
Education
ENEB Business School US
Master’s in Business Administration (Enrolled)
Cheyney University of Pennsylvania
Bachelor's Degree, Business/Commerce 1994 - 1996
Pennsylvania Business Institute
Associate of Arts (AA), Business Administration and Management 1992 - 1994 Licenses & Certifications
Introduction to Quality Management - Alison – Empower Yourself Certificate #1-340-***-****
Six Sigma Lean Black Belt Professional - Management & Strategy Institute Certificate #39655076
Six Sigma Champion Certified - Management & Strategy Institute Certificate #39655074
Skills
Leadership & People Management • Team Building • Conflict Resolution • Training and Development Operational Excellence • Lean Manufacturing • Continuous Improvement • Process Optimization Quality Assurance • Budgeting & Financial Acumen • Budget Management • Cost Reduction Profit and Loss (P&L) Management • Technical Knowledge & Industry Expertise Manufacturing Processes and Equipment • Inventory and Supply Chain Management • Regulatory Compliance Analytical & Problem-Solving Skills • Data-Driven Decision Making • Root Cause Analysis Project Management • Communication & Interpersonal Skills • Cross-Functional Collaboration • Negotiation Adaptability & Strategic Thinking • Change Management • Strategic Planning • Crisis Management Safety & Risk Management • Safety Protocols • Risk Assessment
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