Manufacturing Operations & Maintenance Leadership

Brett A. Barnett

*** **** **** ******

Morganfield Kentucky 42437

Cell Phone 270-***-****

Email **********@*****.***

OBJECTIVE

I am looking for a long-term opportunity that is challenging in any of the areas of Maintenance, Production, or Engineering. One with excellent growth potential that will lead to a mid or upper-level management position where a sense of urgency and leadership is mandatory along with safety and quality as the goal.

WORK HISTORY

03/2025 to present. Substitute Teacher, Union County Public Schools, I have been filling in as a substitute teacher on an as needed basis covering for absences for the local Middle School and High School due to an extreme teacher shortage in our school district for the last year and a half. I teach various subjects throughout the day.

09/2023 to 11/2024. Press Bay Production Coordinator, Metalsa, I managed the daily operations of the stamping press bay consisting of a 3 shift 24-hour operational schedule. I had 6 salaried Group Leaders and 12 hourly Team Leaders that reported directly to me along with approximately 140 hourly UAW indirect reports. We manufactured truck body frames for the automotive industry.

07/2022 to 09/2023 Section Manager, Cleveland Cliffs, I managed the daily operations of the Continuous Cold Mill and Continuous Galvanizing Line and all associated production/scheduling demands associated with these processes. I had approximately 50 hourly UAW personnel and 10 skilled trades maintenance workers that reported directly to me. I worked directly with our corporate operations/scheduling department to insure we were meeting our customers requirements.

09/2020 to 07/2022 Site Manager/Metrology Technician, Cross Precision Measurement, I managed the calibration and testing responsibilities for an embedded company at DANA Corporation in Henderson KY. My daily duties were to ensure all test equipment and tools were to customer specifications. I tested all welded products to ensure proper hardness and braze profiles. I also tested all painted products to verify customer contract specifications for depth and viscosity.

06/2019 to 03/2020 Production Operations Manager, Camaco LLC, Responsible for all the daily production operations to a supplier for Ford Motor Company. We manufactured the internal seat frame assemblies for the Ford Explorer. I coordinated all intra-departmental meetings throughout the day and afternoon shifts. I kept track of all status board KPI’s and production line status with Maintenance Manager to expedite breakdowns. The plant had 8 high speed production assembly lines. I had 7 salaried supervisors along with 350 hourly associates that reported directly to me across both shifts.

10/2017 to 06/2019 Electrical Maintenance Crew Leader, Alcoa Warrick Operations, Newburgh IN, I managed the day-to-day electrical crew repairs for an aluminum smelter. This included a crew of 15-20 hourly union electricians that helped maintain and make any repairs necessary to facilitate production needs. We performed Preventative and Predictive inspections on all associated equipment. I performed daily safety audits/inspections and toolbox talk crew meetings along with weekly production scheduler meetings.

03/2016 to 10/2017 Maintenance Manager, RTP Company, Henderson KY, I managed all daily maintenance functions at a local plastics compounding company. We supplied formulated carbon black product to various plastics companies in North and South America. I was responsible for tracking equipment downtime issues, spare parts inventories, equipment modifications and upgrades. I also interfaced with outside sourced contractors on any facilities projects.

11/2014 to 03/2016 Maintenance Manager Comac Division, Gibbs Die Casting, Henderson KY, I was responsible for all maintenance functions in a 3-shift precision machining plant that provided parts for the automotive industry. We primarily manufactured transmission/differential components for the automotive industry and supplied parts to Ford, Chrysler, GM, Honda, and Toyota. I had 3 shift supervisors, 28 skilled trade employees, and a parts/warehouse/tool crib manager that reported to me. I managed the departmental budget and reported directly to the Plant Manager along with the company’s upper management team. I was in the process of rebuilding and implementing a CMMS and Preventative Maintenance program.

05/2012 to 07/2014 Maintenance Shift Supervisor, Aleris International, Hawesville KY, I was responsible for all the maintenance functions at Aluminum Rolling Mill operation. My direct areas of responsibility were two casting houses, hot rolling mill, mobile equipment repair shop, and warehouse. I had to prioritize maintenance repairs along with Production management to be the most effective and efficient to minimize downtime while increasing equipment efficiency. I also conducted daily audits to make sure that all work was completed in a safe yet timely manner. I had 16 direct skilled trades’ reports that included electricians, mechanics/millwrights, shipping clerks, and auto mechanics.

07/2010 to 05/2012 Maintenance/Production Crew leader, Rio Tinto Alcan, Sebree KY, I managed all the daily operations at an Aluminum Smelting operation. I performed safety inspections, scheduled Preventative Maintenance inspections, and ensured all breakdowns were handled in a timely and safe manner. I also conducted daily tailgate meetings to schedule Production personnel and assign work throughout the department. I managed 25-30 skilled trades and production personnel to drive accountability and sustainability for operational requirements. I also managed a monthly Maintenance budget for all associated parts and repairs for the department. As a Production Crew Leader, I managed the daily operations in the Pot line area which entailed coordination between several departments to insure consistent metal flow with minimal downtime.

1/2010 to 07/2010 ROWPU Operator/Roaming, KBR Inc., Joint Base Balad Iraq, I was responsible for the daily operation and distribution of Reverse Osmosis purified water. I inspected all water storage systems and distribution lines as well as checked all associated equipment for any safety related issues. Insured compliance with customer’s needs for Safety and Quality of finished water product in accordance with governing documents (TB Med 577, TAB H, and MNC-1). I supervised subcontract workers on a daily basis during operation of ROWPU units and oversaw that chemicals were mixed and handled using proper PPE while following established safety guidelines (MSDS, Local DOP/SOP). Conducted daily safety briefings and OJT training, (TSTI/AHA). Compiled and disseminated daily water production reports via email and face-to-face meetings during shift change-over using Microsoft Office software (Word, Outlook, Excel, and Power Point). Trouble-shot, repaired, and replaced any defective or failed components found during operation of equipment on a daily basis. All of this was in support of base operations for Operation Iraqi Freedom task force. I completed a two weeklong orientation/training for ROWPU Operators at Baghdad Training Center that covered several different manufacturers of equipment and theories of operation.

6/2009 to 1/2010 Intake Water Treatment Plant Operator, City of Henderson Kentucky Water Utility Department, I operated and maintained the intake drinking water plant for the City of Henderson. I performed hourly laboratory chemical analysis of the raw and finished water to insure the quality of the city water supply. I also made any necessary chemical additions to maintain the proper PH levels and eliminate any viruses or impurities. I made repairs to any failed equipment and tracked chemical usage/inventories. I monitored computer tracking systems (SCADA) to identify any potential water main leaks or breaks and dispatched maintenance crews to perform repairs. I also monitored all storage tanks through-out the city/county to insure proper water levels and pressure for all customers.

6/2006 -12/2008 Machining Area Maintenance Manager and Paint Area Maintenance Manager, The New Chrysler Motors LLC, I accepted a company buy-out offer due to pending plant closure in 2009. Prior to my separation from Chrysler, I was transferred to Kenosha Engine Plant (Jan 08) due to reduction of a production shift at the Detroit JNAP facility. I directly supervised 3 salaried Maintenance Supervisors and general maintenance operations of an engine machining and assembly plant. I worked with outside sourced contractors on general building/facilities improvements and expansions to ensure work was done according to specifications of contracts. Prior to my transfer, I directly supervised all daily aspects of Maintenance operations in the Paint Department and supported production needs for the Jeep Grand Cherokee and Commander Product lines. I supervised 3 salaried Maintenance Supervisors and 10-12 hourly Union skilled trades’ personnel to insure all maintenance issues were handled in a safe and timely fashion. I performed weekly Safety audits, held daily shift pass-on meetings, attended weekly work schedule meetings, verified that all required Quality/OHSA inspections were complete and within specifications. I worked with my Production counterparts to insure through-put targets and Quality objectives were met. I tracked all Preventative Maintenance work instructions to insure their completion and helped with any logistical needs that might arise from these inspections. I managed budgetary issues for my specific shift and tracked against projected yearly expenses for the department as a whole.

4/2001-6/2006 Technical Construction and Maintenance Engineer, Quality Engineer, and Production Supervisor, Super Duty Paint Department, Ford Motor Company, I held position as the Technical Construction and Maintenance Engineer for the last 3 years I was with the company. I directly supervised 35-40 skilled tradesmen in the following areas; Electricians, Pipe fitters, Millwrights, and Predictive Maintenance team. I was responsible for all daily maintenance operations and wastewater treatment for the Paint Department. Prior to this assignment, I held the temporary position of Quality Engineer for 4 1/2 months due to an early retirement. I compiled all daily/weekly quality information using Excel databases. Reported out on all Quality/Defect trends to Plant Manager and visiting corporate officers. Insured compliance to QS 9000 standards and conducted internal audits of all processes. Insured quality was maintained throughout the entire water-based paint application process from phosphate/ecoat bath to the finished product. Insured that all processes were in compliance to QPS/FPS standards, led Continuous Improvement Work Groups and completed numerous Six Sigma projects. I am a project certified Six Sigma "Green Belt" with over 20 completed process, cost, and quality savings initiatives. As a Production Supervisor, I managed the daily operations of one of the newest paint facilities in Ford Motor Company and 50 hourly production UAW personnel. I maintained and insured compliance with 5S standards/audits, monitored team member attendance, and entered production/payroll using TWOS operating system. I tracked production indicators using SPC and SQDCME Matrix System. I also conducted daily safety audits of the all production areas under my control.

1999-2001 Day Shift Lead Production Supervisor, Valeo Engine Cooling Systems, Managed the daily operations of a state-of-the-art production facility and 80 hourly personnel. We manufactured radiators and condensers for Chrysler, Mercedes Benz, BMW, and Honda using the NOCOLOK brazing technique. I was responsible for daily operation and up-keep on two UV powder paint lines. Insured that all processes were in compliance to QS-9000 standards. Lead Problem Solving Groups, maintained 5S standards/audits, monitored team member attendance and entered production/payroll using AS/400 operating system. I worked closely with production controller and shipping personnel to insure on-time deliveries. I tracked production indicators using the Auto Quality Matrix System.

Military Service/Education/Certifications

Electronic Warfare Technician/Maintenance Supervisor, U.S. Air Force 1985-1994, I spent one-year in formal training at Keesler AFB, MS. Assigned after technical school to work as a Ground Maintenance Technician in support of Tactical Ground Intercept Facilit y at Hahn AB, GE for four years. Performed as an Airborne Maintenance Technician (RC-135) at RAF Mildenhall, UK for three years. Also served as Mobility Operations NCO for 3 years in charge of the squadron’s mobility gear and planning field operations for deployment. Last assigned to Edwards AFB, CA where I worked on various R&D Electronic Countermeasures projects with component-level repair responsibilities. I have worked on computer systems from PC’s to mainframes including installations, configurations, and LAN/WAN integration. I am very proficient with all Windows-based systems and MS-DOS. I was a Shift Supervisor in charge of in-shop and flight line maintenance for the last five years of service. I graduated from an extensive one-month Total Quality Management (TQM) course with distinction.

Spent one year in formal training at Keesler AFB MS, in Electronic Warfare Systems.

A.S. Degree in Electronics and Avionics Systems from the University of Maryland and Community College of the Air Force.

Completed my Bachelor’s degree in Business Management, Leadership and Commerce at Murray State University, Murray KY. I plan on furthering my education and will be starting on my MBA in the future as I only need another 7 classes to complete it.

I attended Ford Motor Company corporate internal training for 3 months and have extensive training from the automotive industry in Six Sigma manufacturing/quality principals and am a project certified "Green Belt". I also have 20 years experience in Lean Manufacturing techniques, Kaizen problem-solving principals, and Continuous Improvement Workgroup procedures. I am an Underwriter’s Laboratories certified QS-9001/9002 internal auditor since 1997. I have also been trained and participated in internal and external QS 14001 environmental audits. I am a MSHA certified Dust and Noise collection technician. I am very familiar with MSDS programs including Hazardous Communications, Labeling Compliance, and proper handling/storage techniques. I collected and tracked exhaust stack samples for VOC emissions in accordance with EPA certification in relation to the Clean Air Act. I filed appropriate paperwork to local and Federal authorities to report any possible violations or spills. I have been involved for many years in equipment design and contract specification for process improvements and ergonomic considerations.

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