Operations Leader with CI & GMP Expertise
Resume:
Ronald David Dance
** ********* **, ********, ** 44406
*******@*****.***
OBJECTIVE
A proactive and results-oriented leader with extensive experience in manufacturing and process execution, focusing on continuous improvement, compliance with cGMP, FDA regulations, and EHS standards. Proven ability to build and lead high-performing teams, optimize processes, and enhance operational performance in a manufacturing environment.
EXPERIENCE
General Extrusions Internation, Youngstown, OH
Plant Manager 11/19-Present
Direct and coordinate daily operations of the manufacturing plant focusing on zero harm.
Oversee all levels of staff activity and performance, to include Shipping/Receiving, Quality, Safety, Engineering, Maintenance and Production.
Reduced the number of NCRs by 50% by implementing MRB program to seek out Root Cause and correct.
Took OTD from 32% to 89% and climbing.
Installed and Implemented MES system to collect and monitor machine runtime, using Ignition software.
Corrected issues with process flow by modifying machine layout to allow craftsmen to increase throughput, by way of operating multiple machines per shift.
Improved plant communications, by developing an effective communication protocol with all internal and external stakeholders. My goal was to tear down silos.
Responsible for the coordination and execution of plant shutdowns and outages.
Rolled out full CI program, and trained operations on CI principles.
Participate in Leadership meetings focused on long term strategy and continuous improvement.
Developed and monitored key performance indicators (KPIs) and implemented corrective actions as necessary to achieve production goals. Utilized GEMBA boards (SQCDP) to inform operations, and plant.
L&T Technology Services, Peoria, IL (Multiple Locations) 9/16-11/19
Director of Operations and Continuous Improvement
Strategic, Long term organizational planning.
Development and oversight of Safety, Quality, Engineering, Maintenance and Operations (SQCDP).
Provided solutions and implemented actions during the product development process and established the infrastructure needed for manufacturing.
Developed and tracked organizational KPI’s.
Effectively communicated organizational roadmap to ensure team members were up to date and knowledgeable on organizational goals and direction.
Created specifications for various components and assembly steps, determining production benchmarks, and optimizing manufacturing efficiency, reliability, and throughput.
Provided support in the enterprise resource planning (ERP) development and training and formulating lean manufacturing methods.
Developed financial evaluations of potential major capital investment projects and provided documentation of investment vs payback to company’s senior management.
Implemented overall equipment effectiveness (OEE) metrics to focus attention on key process equipment availability, performance and quality factors.
Restructured BOM's and reduced manufacturing cycle times to increase shop through put for several companies.
Specialized in introduction of Process improvement, Six Sigma facilitation, lean manufacturing, and ISO implementation.
Designed and implemented Manufacturing Control (ERP), Warehouse management, and Data collection systems (MES).
Provided a wide range of industry specific expertise to facilitate delivery of innovative manufacturing solutions for value added process improvements, and sustainable operations.
Columbus McKinnon, Lisbon, OH 9/15-9/16
Sr. Manufacturing Manager – Operations, Engineering and Maintenance
Support daily hoist manufacturing operations, regarding all technical and operational improvement initiatives. Direct Engineering team on company engineering initiatives.
Project Lead on all Capital Projects ranging from $5K and up.
Developed a “One Piece Flow” assembly line for five different manual hoists, which were previously manufactured utilizing “bench build” methods. Cost savings of $200K in the first year.
Monitor and improve machine tooling practices and usage.
CNC programming, using Esprit, for both Turning and Milling (Including Multi-Axis Machines)
Technical support for Machining department
Part validation/PPAP for new product lines. PFMEA’s used to develop better standards for product launch.
Resolve technical and quality issues as they arise.
Supervise the daily activities of maintenance crew.
Responsible for all building and grounds maintenance and upkeep
Champion all Corporate Lean Initiatives
Mid States Technical, Davenport, IA 11/06-9/15
Sr. Contractor – Engineer/Continuous Improvement & Lean Manufacturing Implementor
Contracted by top manufacturing organizations (Toyota Motor Manufacturing, Honda, Harley Davidson and International Bus Plant) to supply advanced engineering and lean manufacturing principles to help improve overall organizational excellence. Complete CI roll outs.
Engineering, Lean Manufacturing, and Project support for major manufacturing companies.
Process development and improvements for Machining, Fabrication and Assembly processes.
Documentation creation to support existing production lines, as well as new product launches.
Time and Motion Studies (Traditional/MOST/MODAPTS).
CNC Programming and program modifications to sustain production operations.
Manufacturing and Quality support for all operations. Waste Reduction and throughput improvement.
Process validation to include IQ/OQ/PQ for Ultrasonic Welding of plastic cartridge for medical equipment.
Procurement of equipment (Spec and Capital Justification) and Complete Installation.
Validation of Process per FDA Regulations.
Assumed Interim Operations Manager Position.
Effectively manage international supply chain.
Duties to include Material Management, Operations, Mfg. Engineering, Maintenance, Facility and Service.
Manufacturing Engineering Project Management.
Madison Precision Products (Honda Motor), Madison, IN 8/04-11/06 Assistant Plant Manager – Machining and Die Casting
Managed hourly associates and technical support staff.
Presented new model updates to the manufacturing team and management, both internal and customer
Assisted in the daily operation of a three-shift machining department in Aluminum Automotive Manufacturing
Focused on improving line throughput with process improvements and engineering solutions.
Evaluation of current equipment and recommendations to upper management on future equipment purchases.
Lead Capital Investment projects from inception to completion, including hands-on vendor negotiations for dozens of machines ranging in budgets from $100K to $1 million.
Championing Lean Tools to improve throughput and decrease waste.
Reported daily production, safety, and efficiency issues within the department to upper management.
Reported monthly department results of manpower, quality results at customer, in-house rejects, efficiency, capital expenditures, consumables cost vs. budget, repairs and maintenance cost vs. budget.
Prepared and presented problem solving reports utilizing 5P (similar to Kepnor Tregoe) format.
Japanese style management system, focusing on Lean Manufacturing and Total Quality Management (TQM)
New Model Project Engineer
Project leader on several new model line parts for 2006 model year automobiles
Cradle to grave project planning for Aluminum Die Cast parts.
Process development for all Engine and Transmission components. Machine selection, line development, and complete Quality documentation to support production. (i.e., PFMEA’s, Control Plans, Work Instructions, and Process Flow)
Created, updated and tracked project schedules to ensure projects finish on time and within budget.
Investigation and allocation of new model capital equipment
Collaborated with all internal departments to ensure new model parts will be cost effective and maintain high quality standards.
Direct customer contact dealing with all quality issues and technical part reviews.
Total involvement of product line from inception through mass production
Supervised department leader’s activity to ensure on-time completion of tasks.
Stahlschmidt & Maiworm, an Aluminum Automotive Wheel Manufacturer, Auburn, AL 7/03-8/04
Area Manager – Machining
Lead strategic efforts for the start up of fully automated CNC machining cells, capable of producing 2.3 million wheels annually.
PPAP Validation, Quality Documentation creation, to include PFMEA’s, Control plans and Process Flow Diagrams
Maintain CPK 1.67
Part programming using SmartCam.
Internal champion responsible for all Lean Manufacturing initiatives.
Trained salary and hourly team members in all aspects of their jobs, as well as the importance of being a flexible, highly efficient team.
Utilized my diverse background in engineering to ensure the most efficient process possible by reviewing and reducing cycle time and constantly evolving current methods to ensure the highest throughput, with the least amount of scrap possible, by way of Lean Manufacturing principles.
Lexington Die Casting, an Aluminum Die Casting Automotive facility, Lakewood, NY 1/03-7/03
Shop Foreman
Responsible for the daily scheduling of equipment to ensure customer needs are met.
Advised, coached and counseled hourly team members on issues pertaining to performance, conduct, discipline and attitude.
Improved operating efficiency by 30% in the first three months.
Evaluated the need for process improvements on the Die Cast floor with regards to metal flow and die improvements and gave recommendations to the management team.
Evaluated and improved productivity of the secondary machining department, by way of cost-efficient process flow techniques, and developed Standard Operating Procedures to support those improvements.
Accuride Corporation, an Aluminum Wheel Manufacturer, Erie, PA 6/00-1/03
Area Manager – Machining
Responsible for the day-to-day operation of a fully automated machining department, equipped to support a global organization with $111.4M in annual sales.
Accountable for the supervision and training of union team members for the daily operations of fully automatic CNC machine lines.
Maintain 1.67 CPK
PPAP
Key role in creating and developing the manufacturing Process’s to produce fully machined Aluminum Truck Wheels.
Cost Improvement Leader for Capital Improvement projects involving Coolant Recovery resulting in an annual savings of $100,000.
Improved productivity of machine department by 65% over a five-month period.
Decreased waste in department by 55%.
Continuous evaluation of automated machining process to improve quality, safety and productivity.
Part program modifications and editing
Defined standards and expectations for new machining department.
Responsible for the development and implementation of SOP’s (standard operating procedures), Quality documentation to support QS9000 and JSP’s (job safety practices) to support plant wide safety program.
Certification in APQP/PPAP documentation. Created all associated documents to support quality system and launching of new product lines, including all PFMEA’s, Control Plans and Process Flow Diagrams.
Key role in maintaining open lines of communication and detailed coordination with vendors for all aspects of Turnkey Operation.
Developed a comprehensive Preventative/ Predictive Maintenance Program for all machine department equipment.
PHB, Incorporated - Aluminum and Zinc Die Casting, Fairview, PA 3/95-6/00
Corporate Estimating Engineer/ New Product Development
Estimate and quote new job accounts using advanced software to secure future growth for a company with over $100M in annual sales and maintain competitiveness.
Responsible for corporate estimating of aluminum and zinc die-castings.
Accountable for all Machining Division Estimating.
Spearheaded corporate estimating for Plastics and Rubber Division.
Manufacturing Engineer/ Project Leader - Machining Division
Critical role to provide machining expertise in the development of new projects and Improvement of existing processes.
Strategic planning with customers to continuously drive Cost Reduction Efforts.
Focused on Process Improvements and Efficient Product Flow.
Investigated mechanical and electrical downtime issues for equipment and was responsible for bringing them back online as quickly as possible.
Consultant to Programmers and Set-up Machinist on machining applications.
Programming for Turning centers and milling machines, using standard G&M Codes
Reduced overall machining scrap by 45% in a 12-month period.
EDUCATION
Edinboro University of Pennsylvania, 3/2 Engineering - Mechanical
Penn State University Erie – The Behrend College – Mechanical Engineering.
ICS – 2.0 years Electrical Engineering – Associate Program
SKILLS/CERTIFICATIONS
Lean Manufacturing Certification
CPK (Automotive) 1.67
Building self-sufficient teams
Project Management
Change management.
Electrostatic Discharge Certification
Total Quality Management (TQM)
Process Improvement/Development
Okuma lathe programming
Fanuc Robot Op./Programming Certificate
PPAP Documentation/ APQP Certification
PFMEA/SPC/Control Plans
ESPRIT CNC Programming Certification
CNC Programming Certification
GD&T Certification
SMARTCAM Operation Certification
QS Internal Auditor Certification
Six Sigma Green Belt (University of Dayton)
Drucker Institute Training
Running Effective and Efficient Team Meeting
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