Results-Driven Plant & Operations Leader

JOHN HOSBACH

PLANT MANAGER DIRECTOR OF OPERATIONS MANUFACTURING LEADER

Murrells Inlet, SC 330-***-**** *********@*********.*** www.linkedin.com/in/john-hosbach-ssgb-lss

PROFESSIONAL SUMMARY

Manufacturing executive with extensive experience leading high-volume extrusion, plastics, and fabrication operations. Proven people leader with full P&L ownership, workforce development responsibility, and cross-functional execution aligned to business strategy. Expert in OEE optimization, Lean transformation, CI/Kaizen, extrusion process control, ERP-driven scheduling, maintenance optimization, and KPI management across safety, quality, delivery, and cost. Track record of turning around underperforming operations, improving throughput, reducing scrap, managing multi-million-dollar budgets, and leading teams in complex, high-mix manufacturing environments.

CORE COMPETENCIES

Plant & Operations Leadership Manufacturing Operations Management P&L Ownership & Cost Control Budgeting, Forecasting & Margin Improvement Lean Manufacturing & CI (Kaizen, 5S, Waste Elimination) Six Sigma / DMAIC Production Planning, Scheduling & Capacity Management KPI Management (OEE, Safety, Quality, Delivery, Cost) Safety Programs, OSHA & EHS Compliance Quality Management Systems (QMS), Process Control & CAPA Supply Chain, Procurement & Vendor Management ERP / MRP Systems & Data-Driven Reporting Inventory Control & Material Planning Capital Planning, Equipment Strategy & Maintenance Optimization Workforce Development, Succession Planning & Performance Management Cross-Functional Leadership & Change Management S&OP & Demand Alignment

PROFESSIONAL EXPERIENCE

SCREENTIGHT – Georgetown, SC

Plant Manager 2022 – Present

Plant Scope: 180,000 sq. ft. 100+ employees 6 extrusion lines 8 assembly/fabrication areas $60–80M revenue

Leadership Scope: Direct oversight of production, maintenance, quality, safety, and warehouse leadership teams; hiring, performance management, development, and succession planning.

Delivered 10% year-over-year production growth by tightening workflows, improving accountability, and executing Lean fundamentals.

Improved operational efficiency 22% and reduced unplanned downtime 12% through process discipline and maintenance optimization.

Reduced material waste 30% through process redesign and continuous improvement initiatives.

Negotiated supplier agreements delivering a 16% reduction in procurement costs.

Reduced supply chain lead times 15% through improved planning and vendor performance.

Implemented KPI dashboards across safety, quality, delivery, cost, and productivity to drive daily decision-making.

Sustained zero-recordable safety performance for two consecutive years.

Established standard work, escalation paths, and clear expectations to strengthen accountability.

KEENE VILLAGE PLASTICS / 3D SYSTEMS / VILLAGE PLASTICS

General Manager / Plant Manager 2013 – 2022

Plant Scope: 35,000 sq. ft. 15 extrusion lines 35 employees ~$6M revenue

Leadership Scope: Full responsibility for production, maintenance, sales, quality, and administrative functions.

Owned full P&L responsibility for extrusion and assembly operations, staffing, scheduling, and cost control.

Executed startup and relocation of a new manufacturing facility with zero production downtime.

Increased productivity 60% and improved quality 50% through assembly redesign and process control.

Sustained CPK >1.33 across extrusion operations through SPC and corrective action.

Expanded customer demand 55% while maintaining 97% on-time delivery.

Built a stable workforce with employee turnover below 2%.

Developed supervisors and managers, creating bench strength.

Presented KPI-driven performance and improvement plans to executive leadership.

THERMO-RITE MANUFACTURING INC. – Akron, OH

Plant Manager 2011 – 2013

Stabilized high-mix, low-volume job-shop operations across welding, press, distribution, and assembly.

Integrated MAS90 ERP into production scheduling, improving workflow visibility and eliminating duplicate work orders.

Developed multi-level Bills of Material achieving inventory variances under 1%.

Implemented vendor quality scorecards to improve supplier performance.

Delivered $22,000 in annual operating cost savings through energy-efficiency initiatives.

Aligned production planning and inventory control with customer demand.

BRIGHT IDEA SHOPS / THE PLASTIC LUMBER COMPANY – Akron, OH

Plant Manager 1993 – 2011

Plant Scope: 175,000 sq. ft. 65+ employees 15 extrusion lines 24/7 operations

Led 24/7 extrusion, fabrication, maintenance, quality, safety, and logistics operations.

Improved overall plant productivity 45% while reducing scrap and rework 50%.

Executed plant consolidation improving efficiency 43% with no capital investment.

Improved labor deployment, line balance, and equipment utilization to increase throughput.

Reduced freight costs and improved delivery performance through logistics negotiations.

Partnered with executive leadership on forecasting, material planning, and new product launches.

Evaluated capital and process investments using ROI and operational impact analysis.

EDUCATION, CERTIFICATIONS & TRAINING

Villanova University – Six Sigma, Lean Six Sigma University of Akron – Coursework

Lean Six Sigma Green Belt Lean Six Sigma Manufacturing OSHA General Industry ERP Systems: MAS90, Oracle, Sage Microsoft Excel, Word, Outlook

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