Production Manager

Jeffery J. Jones

*** *. **** ******, *********, Indiana 47904 765-***-**** **********@*****.***

MANUFACTURING AND OPERATIONS LEADER

Driving profitability through team engagement, alignment, process optimization and innovation.

Manufacturing and Operations change agent with uncompromising commitment to safety, quality and customer focus. Emphasis on aligning goals, growing results-driven cultures and maintaining sustainability. Strengths include simplifying operations and developing self-directed work teams.

Data-Driven and Results-Oriented

Production/Operations P&L

Total Quality Management

Total Productive Maintenance

KPI and Policy Deployment Leader

Six Sigma Black Belt

Over 100 Lean Implementations

Safety Programs Expert

Chemical Plant Startup

Project Management

Leadership Highlights

As Operating Systems Manager, in just 10 months, reduced customer complaints from all-time high to zero by engaging cross-functional team, redirecting facility to be customer-focused and building trusted business partnership with customer. Sustained for 19 months straight.

As Managing Consultant, set up and managed “TeamRoom” space for all IBM Project Executives (PE) to manage their project performance. Member of core business team who completed monthly financial reviews of all Public Sector Federal, State and Local projects.

As Plant Manager, reduced die-changeover process from 2 hours to less than 5 minutes resulting in 49% increase in weekly shipments.

As Vice-President and General Manager, redirected business back to core-competency and implemented pull system to improve flow of cabinets resulting in over 200% increased production and sales for this turnaround. Positioned Venture Capital group to sell the business.

Additional Milestones

Improved safety: Set two unprecedented plant safety records for length of time without a Lost-Time-Accident (over 5 years) and reduction of Total Incident Rate (TIR) to zero.

Increased overall plant productivity: Streamlined changeover process by 8 minutes resulting in daily shipment increase of 2.5 truckloads per day. Implemented 4 new cutting-edge technologies which eliminated the human-factor variations in product sampling results. Instrumental in setting 21 production records in less than 4 years. Reduced upstream office processing steps from 196 to 11 within first 3 months.

Reduction of in-house inventories: Reduced over-production of paper board and obsolete inventories by $630,000. Eliminated die-inventory valued at $153,000.

Employment History

Subaru of Indiana Automotive (SIA); Lafayette, Indiana 2020-2024

Contracted Onboarding Instructor (Technical Training Center)

Achieved goal of doubling stagnated Associate retention rate for all direct hire, direct hire military and temporary Associates.

Provided Fundamental Skills Training and physical conditioning to fully prepare each Associate for their upcoming successful career.

Performed individual analysis on why each Associate came to SIA, what they hope to achieve and helped them connect their why to the organization so they were able to fully engage with open communication of ideas, issues and resolutions.

Trained and prepared Associates for working in a Team environment by explaining in detail each pillar of the business so they understand their part and fully participate at a high level. Recognized by manufacturing management for outstanding contributions in these areas.

Ball Corporation; Monticello, Indiana 2012-2016

Operating Systems Manager

Provided hands-on training in Statistical Process Control (SPC), Problem-Solving, Root-Cause Analysis and Maintenance to all salaried and non-salaried employees.

Managed all Quality, Production, Maintenance and Engineering systems, teams and visual management aids in facility. Responsible for initial SQF certification and daily management.

Provided all data, analysis and recommendations using Lean Six Sigma methodologies.

IBM Corporation; Lafayette, Indiana (remote -- home office) 2007-2011

Managing Consultant – Lean Six Sigma, Strategy & Change

Streamlined process for IBM Global Business Services (GBS) employees rolling on/off projects resulting in cycle time improvements and higher productivity.

Performed executive-level monthly reviews of all Public Sector GBS projects to ensure projects were on task and within budget. Brought closure to all open issues identified.

Designed and developed standardized, closed-loop complaint handling system for the State of Indiana. Implemented a sliding-scale fine assessment for missed KPI’s.

Led initiative to address how IBM handles distribution of public and private personal documentation resulting in elimination of inconsistencies and legal issues.

Package Right Corporation; Tipton, Indiana 2003-2005

Plant Manager

Acquired 3 competitors within first 18 months to strategically position business for market superiority and sale. Sold and now currently the largest private-label supplier of jigsaw puzzles and board games in the United States.

Performed Value-Stream Analysis and completed 3 key projects resulting in improvements to Safety, Quality, Productivity and weekly shipments.

Broke down barriers with supplies to allow business to receive smaller more frequent shipments and deliveries of raw materials.

Dwyer Compact Kitchens; Michigan City, Indiana 2002

Vice-President and General Manager

Implemented a supermarket-style pull-system for all components resulting in increasing daily output by over 200% -- promoted from Vice-President of Manufacturing to Vice-President and General Manager.

Realigned core competency of the business to get back to producing standardized components and cabinets for our military base installations.

Lowered operating costs 14% by eliminating non-value-added activities.

Trained unionized Steel Worker teams on Problem-Solving tools resulting in improvements to customer satisfaction and reduction of customer complaints by 80% within 90 days.

Project achieved goals one month early positioning the VC group to organize the sale.

ThyssenKrupp Automotive; Danville, Illinois 2000-2001

Sr. Operations Manager, Presta Division

Directed two business units with over $41 million in P&L responsibility.

Supervised and managed 12 direct reports.

Served on the 12-member Senior Management Advisory Board giving direction to four plants representing two divisions.

Champion of five successful cross-functional lean projects. One SMED project resulted in $570,000 of increased annual production. A second project reduced in-house raw material inventories by 28%, streamlined the die-ordering process and removed $153,000 of die inventory.

Improved quality and customer relations resulted in Presta business unit being recognized as “Supplier of the Year” by Dana Corporation, a multi-billion dollar customer.

Designed and implemented a multi-dimensional Continuous Improvement project matrix to ensure all business units ramped up together and not independent of one another.

Successfully negotiated the transfer of $5 million of business from France, Luxembourg and Germany to the United States to eliminate product delays tied up in customs.

Recognized by fellow senior managers for my contributions and improvements to alignment of human resources and the annual review process to keep focused on KPI achievement.

Connectronics, Inc.; Edinburgh, Indiana 1998-1999

Manufacturing Manager

Responsible for all manufacturing activities related to the military and consumer goods business segments.

Developed a simple and effective system of plant-wide policy deployment deliverables used to measure all key indicators driving the business.

Defined roles and responsibilities for every job classification in the organization then appointed team leaders to manage the daily activities. Once goals were set the teams delivered in excess of $541,000 in annualized improvements within the first 6 months.

Reduced internal scrap by 22% and increased hourly productivity by 31%.

Valeo Engine Cooling; Greensburg, Indiana 1996-1998

Valeo Production Systems (VPS) Engineering and TPM Supervisor

Managed all plant-wide lean manufacturing, continuous improvement and TPM activities in a 350,000 SF facility with over 990 associates and $380 million in annual sales.

Formally trained internationally as a hands-on lean implementer/trainer and carried out all lean implementation at the Greensburg facility, sister plants and with suppliers.

Educated and trained over 200 personnel and staff members on lean tools such as 5S, TPM, SMED, Kanban, Continuous Hoshin and Value-Stream-Analysis.

Championed and designed the installation of 16 poka-yoka devices to eliminate the potential for human error.

Responsible for implementing the first SPC tool in the organization.

Team lead that successfully implemented QS-9000 certification and conducted all internal and external auditing for the entire value-stream.

Facilitated more than 20 highly-focused lean workshops aimed at elimination of waste.

Managed the groups responsible for all future compliance related to the gains realized during the workshop activities.

Manufacturing Supervisor (promoted to VPS Engineering and TPM Supervisor)

Directly supervised 45 manufacturing Associates and Group Leaders.

Trained five different self-directed autonomous work teams.

Led numerous Problem-Solving Groups (PSG’s) and Continuous Improvement (CI) teams. One of these PSG’s resulted in line efficiency improvements of 19% in the first 18 weeks.

Lowered scrap rate from 1.6 to.07% as a percentage of sales.

Decreased customer returns from 126 to Zero PPM in 19 months.

Assisted the Nocolok Business Unit Manager in writing the policy deployment strategy plan for his $67 million business unit.

Promoted to Production Systems Engineering and TPM Supervisor.

Selected Key Courses and Training: SQF/HAACP/ISO/QS implementations, Risk Management, Adult Learning Principles, SAP/JDE, Internal/External Auditing, Facilitation, Self-Directed Work Teams, Franklin Covey Time Management, Structured Teamwork and Organizational Leadership.

Bachelor of Science Degree – Purdue University

Organizational Leadership and Supervision; West Lafayette, Indiana

Contact this candidate