Quality or Manufacturing Management
Resume:
Gary R. Ford
Bristow, OK 74010
Cell: (423) 244--5579 Email: ********@***.***
Summary of Management Experience:
Growth, start-up, and turnaround experience in international companies. I have provided leadership in award winning companies who received the Deming Prize, Wisconsin TQM Manufacturer of the Year Award, the (TPM) Total Predictive Maintenance Prize from Japan’s JIPM, ISO 9000, QS, TS registrations, and recognition for applied (TPS) Lean Manufacturing Techniques. Proven experience in Operations, Administration, Finance, Engineering, and Sales & Marketing restructuring in U.S. and Asia (China, Japan, and Malaysia).
30 Years Manufacturing experience
26 Years Lean Manufacturing (TPS)/Operations process/systems experience
20 Years Executive Level P&L experience
6 Years Sales and Marketing experience
Education:
1996 MBA University of Indianapolis - Operations and Finance
1980 BS Austin Peay State University - Industrial Engineering Technology
Professional Experience:
07/2023 – Present Detention Officer
Creek County Juvenile Justice Center in Bristow, OK Ph: 918-***-****
Control Detainee movement, facilities contraband searches, and lock in procedures
Physically manage difficult Detainees
Store, secure, and release Detainees personal property
Process and document Detainees through Intake
Provide security for staff, visitors, and Detainees
Monitor Security Cameras
Feed Detainees
Provide Laundry service
10/2022 – 06/2023 Mental Health Security Officer
Moccasin Bend Mental Health Institute in Chattanooga, TN Ph: 423-***-****
Patrol facilities and grounds
Physically manage difficult patients
Store, secure, and release patient personal property
Process and document patients through admissions
Provide security for staff, visitors, and patients
Control access to property
8/2021 – 10/2022 Licensed Armed Security Officer
Walden Security (Chattanooga, TN) Rhea Medical Center (Present) and Nokian Tyre in Dayton, TN
Monitored security cameras, Patrolled, Controlled access to all facilities, and Managed difficult patients/visitors
5/2019 – 7/2019 Corrections Officer
Core Civic (Silverdale Detention Facility) Chattanooga, TN
Controlled inmate movement, Transport, Facilities contraband searches, and lock in procedures
Developed Neuropathy and had to leave until it was controlled by medication.
3/15/2015 – 12/22/2018 Caregiver
Put career on hold to stay home with my critically ill wife.
2/2/15 – 3/14/2015 President
Nitro Fiber LLC – Provided Operations support for the start-up of a Fiber Optics cable company.
Short term contract assignment
7/21/2014-1/30/2015 Managing Director (Shanghai, China) Park Ohio Industries
Contracted to Turn around Fluid Routing Solutions Automotive Tier 1 Fuel filling systems and Tier 2 rubber injected molded components.
•Monthly EBITDA increased 15%
•40% Productivity increase
•Past due shipments reduced from 54% to 0
•Successfully launched three new products
Completed turn around
5/20/2013 – 7/18/2014 President/COO (Assisting partner with Start-Up)
Barham Motors LLC – Electric Automobile Start-up Company in Seattle, WA
Developed the Financials, Marketing Plan, Operations/Production Plan, and Investor prospectus. Prepared and presented the Business Plan to potential investors.
Company Start-up did not acquire sufficient funding to proceed
3/1/2011-5/16/2013 Vice President of Manufacturing
Toho Tenax America – A $60 Million, 24/7 Carbon Fiber Manufacturer to Aerospace, Leisure, and Composite Industries. Responsible for direct reports in Manufacturing, Quality Management, Manufacturing/Process Engineering, Purchasing/Logistics, Plant/Facilities Engineering, and Environmental Safety and Health. The Manufacturing organization has 12 Salaried and 145 Hourly employees.
Accountable for $33 Million Manufacturing Budget and $2.1 million in annual Capital expenditure
Reduced manufacturing cost by $2.1 million in 2012 by reducing operational and Equipment down time through the introduction of Total Preventive Maintenance
Increased 24/7 production campaign from 15 to 28 days with statistical process analysis and reduced start-up material loss from 10 tons per run to 5 tons for a savings of $288,000 annually.
Increased product line yield by 30%
Reduced product line start-up time 42% with process mapping, improved maintenance schedule, and method analysis
Developed Energy Conservation Program which reduced electric energy cost by $150,000 annually through replacement of facilities lighting
Introduced Strategic and Operations planning for accountability in achieving Key Performance Indicators
Manufacturing moved to Japan
01/29/2010 – 03/01/2011 Pursuing an opportunity in a Manufacturing organization
04/07/2008- 01/29/2010 Director of Quality and Materials Management – Dometic Environmental Marine - Metal fabrication, Electronic Controls, and Assembly. Organization was a $90 million supplier of Marine Environmental Systems with 161 employees in (2) plants.
Implemented Product Process/Dock Audits to reduce internal rejects 25%
Inventory absolute dollar variance improved 4%
Inventory absolute quantity accuracy improved 9.5%
Reduced Warranty cost by $700,000 from $2,600,000 in 2008 by leading Quality Management & Engineering in DV/PV, PFMEA, DFM, NPI, APQP, and product/process innovation
Selected Suppliers in China for Air Filtration Components
Implemented Total Quality Management over Quality Control
Introduced FIFO inventory management
Also responsible for Budget, Safety, Hazardous Materials, and New Product Introduction Projects
Produced Division Quality and Materials Management Budgets
Laid off - due to closure of a facility
04/2006 - 04/2008 Director of North American Manufacturing Operations - Johnson Electric – Electronic Controls, Fabrication, Assembly, and Injection Molding. A Chinese owned $270 million OEM Tier 1 Supplier of Actuators, Solenoids, Switches, PWM’s and Power Train Products (FMVSS testing) with 380 employees in (3) plants.
Led Operations with Lean initiatives to include TPM, TPS, Value Stream Mapping, Kaizen events, Kanban implementation, JIT, and Hoshin Kanri for an annual cost improvement/avoidance of 20%.
Led Quality Management & Engineering in DV/PV, DFMEA, PFMEA, DFM, APQP, PPAP, 8D, and DOE to reduce field warranty costs 30%.
Led Lean workshop for our customer (Delphi Automotive) to increase electronics assembly line productivity 31%
Relocated Ford Motor Company Power Train product from Michigan to Tennessee securing 1.5 million in annual Sales
Secured future Tier 1 supply relationship with Ford Motor Company and led New Product Introduction Team
Worked with electric motor product facility in China to resolve chronic resistance welding issue
Worked in Hungary to resolve circuit board motor speed control intermittent failures
Developed and deployed long/short term Operations Strategy using Hoshin Kanri
North American Manufacturing P&L responsibility
Laid off - due to Automotive Industry decline in sales and closure of two plants
04/2004 - 11/2005 President/CEO - ECO-gen LLP
A new company start-up venture to manufacture a patented concept in Organic Fertilizer Products
Developed Strategic Business Plan and (5) year financial profile for investor prospectus
Led Sales/Marketing, plant site selection, facility/equipment specifications, and production/process requirements
Presented Business Plan to potential investors
Corporate P&L responsibility
Venture ended when owners had a dispute over continued investment sharing.
05/2000 - 04/2004 Senior VP Operations/Administration - Sanden International
Japanese owned $400 million OEM Tier 1 Automotive Parts Supplier with (2) plants (Die Cast, Machining, and Assembly). I was appointed as an Advisor to the Japanese President in developing and deploying a strategic plan to turn the company around. Led re-organization of the company structure with full P&L accountability to achieve profitability.
Non-conforming/obsolete/slow moving material reduced from $6 million to $320K by promoting aftermarket sales and introducing Kanban
Reduced annual inventory variance from $2 million to less than $100K
Developed and led strategic initiatives to improve company profit from a loss of $6 million to a profit of $12 million in one fiscal year
Improved manufacturing operating profit from two to twelve percent in three years
Led company to receive (Total Predictive Maintenance) TPM Excellence Award from Japan in 1.5 years
I was selected by Corporate to lead a team of Global Business Leaders to develop a Global Corporate Culture through analysis and deployment of cross-functional Operating Systems.
Appointed as Chief Ethics Officer and was a member of the Board of Directors in U.S. and Mexico
Introduced the use of Hoshin Kanri for long/short term Strategic deployment
U.S. Corporate P&L responsibility
Joined Start-up Venture after 4 months part time consulting for ECO-gen LLP
04/1998 – 04/2000 Vice President and General Manager - Dunham-Bush Inc. International -A Malaysian owned Commercial and Industrial HVAC Manufacturing Company with (2) plants (Metal Fabrication, Welding, Assembly, and Controls) I reported to the Chairman of the Board in Malaysia and was contracted by the Board of Directors to affect a two-year turnaround. Led the company from $35 million sales with $6 million loss to $50 million sales with $2 million profit in 25 months.
Sales per employee gain from $250K to $595K
Manpower reduction from 140 to 84
Inventory reduction of 30% utilizing Kanban implementation and Supplier/Customer relations Team
On time shipments improved from 78% to 98% deploying and leading Lean initiatives such as TPM, TQM, TPS, Value Stream Mapping, Kaizen events, and JIT
Restructured Sales and Marketing to regional concept
Introduced the use of Hoshin Kanri
Moved manufacturing operations to Mexico from Virginia
U.S. Corporate P&L responsibility
Left the organization after the (2) year contract concluded- Did not want to re-locate to Mexico to manage South American Operations
09/1993 - 04/1998 Director of Quality and Technical Services (1993-1996) Operations Manager (1996-1998) - Carrier Corporation of United Technologies -Residential HVAC (2) plant division with sales of 1.1 billion (Metal Fabrication, Assembly, Controls)
11/1989 - 09/1993 Vice President of Total Quality Management and Customer Service - Accurate International-Dry material metering custom products (Metal fabrication, Assembly, Welding, Electronic Controls)
1988-1989 Director of Quality Management-Burner Systems International Gas Burners and Manifolds- 3 plants (Metal fabrication, Welding, Assembly)
1985-1988 TQC Manager and Manufacturing/Process Engineer- Calsonic U.S.A. Automotive Exhaust and Heat Exchange products (FMVSS testing)- 3 plants
Prior to 1985 Johnson Controls- New Product and Plant start up for Nissan- Automotive Seating (Quality Manager), (FMVSS testing), (Manufacturing, Industrial, Safety, and plant engineering positions) Acme Boot - (Injection Molding Supervisor) (Plant Engineering Manager)
Military Service - U.S. Army Special Forces (Airborne)
Contact this candidate