Plant Manager and Operations Leadership

Robert J, Cummins

A skilled Plant Manager and Operations manager, proficient in overseeing all facets of facility establishment and production operations. Key responsibilities encompass crafting business strategies, facility design and execution, budgeting, performance metrics, oversight, workforce management, and personnel administration. 20 Years Plastic- Injection, extrusion, vacuum forming and stamping- Progressive and Hot stamping

Areas of Expertise

●Strategic Growth and Planning ● Just In Time (JIT) Inventories and Part sequencing

●Management of Multi-location Facilities

●Business Development ● Inventory Tracking and Resolution

●Financial Projections and Budgeting ● Lean Manufacturing and Process Flow analysis

●Facility Acquisition and Construction

●Facility Improvements and Management ● System Implementation and

●Supplier Development and Relations Maintenance

●Production and Operation Management Program ● Launch Coordination

Management ● MRP and ERP System Integration

●Process Design and Improvement ● Employee Training and Development

●Program Management ● Team Building Skills

Plant Manager, Sonoco Plastics, 29200 Wall St. Wixom MI, 48393 6/2024 - Current

Recruited to spearhead a cultural transformation within an injection Molding process, driving significant improvements in operational efficiency, increase profitability, and increase workforce retention

•Assessed staffing levels and operational processes to establish strategic production goals, while implementing initiatives to reduce employee turnover

•Revamped management structure and assumed control of scheduling to optimize production planning and resource allocation

•Introduced a production reporting system to track performance and set achievable, data-driven production goals

•Initiated a thorough bill of materials review to ensure seamless integration and accuracy ahead of the new ERP system implementation

•Mentored employees into leadership roles, promoting several to team leads, and collaborated closely with the supervisor to guide his development into the role of Production Manager

•Held full P&L responsibility, overseeing financial forecasting and budget development to drive profitability and ensure fiscal accountability

Plant Manager, Modular Automotive Systems, LLC., 2900 Silverbell Rd, Suite 290 Lake Orion MI 48362 12/2019 – 6/2024

Responsible for four facilities, covering 1.5 million square feet, and accountable for the meticulous assembly and sequencing of OEM automotive components. GM & Stellantis

•Established and efficiently oversaw four state-of-the-art, just-in-time sequencing and assembly facilities dedicated to supporting OEM assembly plants.

•Pioneered the inception of the sequencing division at Hollingsworth, in a partnership with Magna, as an integral member of the founding team responsible for orchestrating part sequencing and assembly.

•Collaborated closely with the team to spearhead the expansion of the division, transforming it from a single program operation in one facility with 100 employees into a second facility focused on JIT into General Motors.

•Significantly boosted annual sales figures from 1 million to an 18 million, concurrently elevating profit margins from a modest 8% to a substantial 17% on average.

•Directed all facets of operations within a multi-plant environment, which encompassed oversight of budget management, human resources, safety initiatives, production, engineering, quality control, inventory management, procurement, and IT systems.

•Spearheaded numerous product launches, orchestrated strategic facility acquisitions, executed essential upgrades, and oversaw pivotal construction initiatives.

•Identified and seamlessly relocated several commodity groups to new facilities, effectively adapting to evolving space requirements.

•Expanded available warehouse space by optimizing inventory management, conducting in-depth production requirement analysis, and implementing innovative storage strategies, thus facilitating the accommodation of new business opportunities.

•Sustained an exceptional 98.5% inventory accuracy rate, achieved through meticulous manual inventory audits and the successful integration of ERP systems, which subsequently reduced the need for physical counts to an annual occurrence.

•Collaborated closely with suppliers and customers to proactively address and resolve quality and delivery challenges, ensuring the uninterrupted flow of materials in our operations.

•Implemented lean manufacturing techniques resulting in a 62% reduction in workforce, optimizing operational efficiency.

•Skillfully crafted budgets and delivered highly competitive, cost-effective quotes for new business opportunities.

•Enhanced business equilibrium by diversifying services with the introduction of cross-dock warehouse storage, metered shipping, and consumer distribution programs.

•Cultivated and sustained outstanding customer and supplier relationships, fostering a collaborative and mutually beneficial network.

•Elevated our facilities from light to medium assembly capability through strategic upgrades and improvements.

•Oversaw installation and integration of several multipurpose machines used in the assembly of plastic products.

•Revolutionized our assembly processes by transitioning from 100% manual operations to a multifaceted approach, incorporating advanced assembly lines and cutting-edge machinery to enhance both quality and efficiency.

•Established robust metrics reporting systems to facilitate the attainment of annual objectives and goals.

Plant Manager Colonial Plastics 51734 Filomena Dr. Shelby Twp. 48315 11/2017 – 2/2019

Managed 2 Injection Molding establishments, and staffing of Two buildings 3 shifts 150 employees. Teir 2 supplier

•Utilizing proven Lean Manufacturing techniques, collaborated with key team members to optimize floor space utilization, resulting in a highly efficient storage system that minimized space requirements.

•Recruited and mentored a highly skilled team of assemblers and engineers.

•Oversaw all aspects of human resources and quality management.

•Consistently upheld an exceptional inventory accuracy rate of 99.6%.

•Collaborated closely with customers to effectively address and resolve issues, ensuring mutually beneficial outcomes.

•Developed an innovative scheduling and tracking system, which efficiently monitored average shipment volumes, build rates, and labor costs, enabling the establishment of precise build goals.

•Designed a dynamic production reporting system that provided real-time notifications to assembly personnel in cases where production fell below specified minimum requirements.

Sr. Process Engineer, Grupo Antolin., 1700 Atlantic Blvd, Auburn Hills, MI 48326 4/2016 - 11/2017

Lead Equipment development from design to delivery for Dodge Ram door Interior

•Directed all operational activities for machine design costing and delivery for over 15 million dollars of equipment

•Adhesive machine for High Volume Tier 1 supplier. Help design and write all work instructions and training

•Vacuum forming machine for high volume door skins aligned with edge wrapping equipment and commercial stitching machines for 4 different models

•Played a pivotal role in product launches and process sign-offs (PSO), ensuring the successful introduction of new products and processes.

•Served as a member of the Material Review Board, responsible for evaluating all suspect materials and leading the successful implementation of corrective actions.

•Effectively managed inventories and conducted comprehensive requirement analyses, resulting in the maintenance of a lean three-day supply and significant reduction in obsolescence.

•Established clear communication channels with suppliers and diligently followed up to ensure requirements were consistently met.

•Efficiently coordinated inventory cycle counts, made essential adjustments, and proactively investigated discrepancies, maintaining an accuracy rate of 98.8%.

•Conducted comprehensive training sessions for team leaders, empowering them with the necessary knowledge and skills to navigate computer systems and leverage system enhancements.

•Played a pivotal role as a key team member in the successful launch of the facility.

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Division Manager, Modular Automotive Systems, 5400 E. Nevada, Detroit, MI 48234 2/2010 – 4/2016

Orchestrated the production scheduling for Jeep grand Cherokee line, coordinating the manufacturing of more than 300 distinct parts.

•Commenced my journey within the company as Division manager over the Jeep Grand Cherokee and Chrysler 200 Programs

•Spearheaded several project teams focused on the crucial objectives of reducing defects and minimizing machine downtime. With savings of over 280k

•Enhanced line capability by a remarkable 20% through strategic programming and scheduling modifications.

•Successfully reduced open orders from an average of 5 days to an impressive 2 days.

•Cultivated and sustained exceptional customer relations while actively seeking opportunities for new business acquisition.

Oakland Community College – Fire Science program Fire Fighter 1999-2000

Alliance Mobile Health- Michigan certified Emergency Medical Technician 2000- 2001

State of Michigan Officer 1,2,3 2004 - 2006

Several ERP and production control systems

SAP knowledge and launch capabilities

Database review and reporting

Warehouse / Plant layout

Quoting and cost analysis

Process creations and management

Material flow and management

Facility upgrades and launch coordination

11110 Hegel Rd. Goodrich MI, 48438 ************@*****.***

Phone 586-***-****

Lean Six Sigma Blue Belt Certification

JOB EXPERIENCE and ACCOMPLISHMENTS

EDUCATION

TECHNICAL SUMMARY

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