Manager Project
Resume:
Kenneth P. Ledoux
Forest City, NC 28043
******.***@*****.***
Professional Accomplishments Profile and Fields of Competence in Plant Management, Quality Management and EHS Management:
• Foundry Plant Manger (120 employees, 3 shift operation, 11 million pounds annually) responsible for annual operating plans, on-time delivery, and production schedules
• Production Manager for injection molding, machining, assembly, packaging, plating, plastic extrusion and green sand foundry and die casting
• Reduced Cost of Quality compared to cost of goods sold 45%
• Reduced Foundry Scrap by 30%.
• Quality Manager for three plant locations totaling over 450,000 sq. ft. and with an operating budget of approximately 22 million dollars per year.
• Reduced the Internal Failure Rate DPM from 14,000 to 4,630 with a CpK of 1.37
• Implemented Standard Work and Quality Alert Systems
• Maintain QMS and QAD Systems
• Maintain multiple Staff Manger Positions simultaneously with positive results
• Establish Assembly and Test Procedures (ATI) to ensure product liability.
• Experienced with compliance and testing procedures with ISO, ASME, ASSE, IAPMO, CSA, UL, NSF, and SAI Global Agencies.
• Experienced at Root Cause Analysis tools to include 8D, fishbone diagrams, five whys
• Experienced in technical writing and procedure writing
• Implemented IDR and SCR for Supplier Continued Excellence
• Experience in the use of inspection equipment to include spectrometers, calipers, micrometers, pin gauges and pressure gauges
• Experienced in Micro Soft Office Software
• Safety, Health and Environmental Manager for four plant locations totaling over 450,000 sq. ft. with an operating budget of approximately 22 million per year.
• Achieved a sustainable world class OSHA incident rate of less than (1) one with more than one million hours of risk per year.
• Maintained multiple staff positions simultaneously with positive results
• Teacher at Becker College, Worcester MA, Environmental Management Program
• Maintained all reporting and compliance required of a Large Generator status to include Hazardous Waste, Air Permitting, Storm Water, Waste Water and DOT.
• Consulting and Training of all safety and environmental programs
• Experienced at emergency medical and chemical spill response
• Certified Trainer CPR, AED and First Aid, American Red Cross
• Licensed Grade Two North Carolina Waste Water Physical Chemical
• Certified Crane Inspector, Crane School of America
• Experienced Industrial Hygienist and Ergonomic and Health Manager
• Facilities and Equipment Maintenance Management
• Environmental Construction, Project Management
• Implemented Ergonomic teams and stretching programs
• Experience in technical and procedure writing
• Experienced in using industrial hygiene measuring equipment to include sampling pumps, sample tubes, dosimeters, pH meters, confined space monitoring equipment, and ventilation measuring equipment
• Experienced as a World Class Manufacturing and Lean Leader and 5S trainer
• Experienced implementing Behavior Safety Programs and the Dupont Stop Program
• Experienced at hazardous waste clean up activities to include Project Management of Superfund sites, sludge dewatering, compress gas remediation, land fill closure, UST extraction, and contaminated soil remediation
• Experienced at Worker Compensation Law and Risk Management
• Experienced Manager (EHS Manager, Foundry Plant Manager, Operations Manager, Quality Manager, Facilities Manager, Project Manager, Procurement Manager)
• Experience in writing Site Specific Health and Safety Plans for Hazardous Waste Sites
• Experience with NIOSH Industrial Hygiene test methods
• Experience working with Federal OSHA, EPA, State NCDOL, DHEC, and NCDENR
Professional History:
Present – Magneti Marelli Powertrain USA – Foundry/ Die Cast Manager
As Foundry/Die Cast Manager, responsibilities include on time delivery, production, P&L budget, maintenance management, die cast tooling management, safety, environmental, quality compliance, and World Class Manufacturing implementation for the Automotive industry (ISO/TS-16949).
Responsible for implementing TWI training work instructions, OPL one point lessons, autonomous maintenance, professional maintenance procedures and standard work instructions.
Die cast operations consist of A360 and A380 aluminum casting utilizing 600 to 1200 ton die cast machines to include Lester, Frech, B&T and Colosio models.
Responsible for Process Control audits, Supplier Chain audits, ISO and other Agency audits.
Upper level tools used are daily Gemba walks, accountability meetings, customer focus and performance reviews on all value streams. Experience include World Class Manufacturing, lean manufacturing process, 8D corrective action, A3 process, PFMEA and Control Plans, PPAP Process and Scar Supplier Corrective Action Request, and SPC processes. Responsibilities include compliance in environmental management (ISO-14001), occupational health (OHSAS-18001) and quality (ISO/TS-16949, the automotive equivalent of ISO-9001).
Magneti Marelli, an Italian-based international subsidiary of Fiat Group that designs, produces and supplies high-tech engine and transmission component systems and modules for the auto industry.
From concept through development, testing and production, Magneti Marelli provides components for major automakers including Chrysler, Ford, GM, VW, Harley Davison and others. The company's offerings include electronic throttle controls, throttle bodies, integrated air-fuel modules and electronic control units.
Past Work History:
1997 - 2012 Watts Water Technologies - NC and SC Operations
Foundry Plant Manger/Quality Manager /EHS Manager
At Watts Regulator, I have held multiple staff positions with positive results. These positions include Foundry Plant Manager, Production Manager, Facilities Manager, EHS Manager and Quality Manager.
Plant Foundry Manager for a Bronze (four alloys), Green Sand Foundry. Management responsibilities included a multiple shift operation with 120 employees. The Plant production requirements were 11 million pounds annually. Responsibilities included annual operating plan, labor, on time delivery, production schedules, quality, maintenance, pattern shop and machining. Foundry equipment included Hunter and Sinto molding machines, Shalco and Redford core machines, rotary separators, Wheelabrator, trim presses, Inductotherm electric induction melting furnaces and auto-pour channel holding furnaces.
Production Manager Responsibilities included multiple shift operations in plastic injection molding, chromium plating, machining, assembly, packaging, tube bending and plastic tube extrusion and connectors, and stamping and foundry operations.
Quality Compliance and Management to (ISO-14001), occupational health (OHSAS-18001) and quality (ISO/TS-16949, the automotive equivalent of ISO-9001, ISO – 9001 - 2008, ASME ASSE, IAPMO, NSF, CSA, and UL Standards. Experience with working with agency auditors, agency procedures and agency testing.
Responsibilities include statistical reporting, QMS maintenance and RGAT investigation, problem solving and testing and QAD / RGAT file maintenance. Maintain systems and reporting for trend analysis to include defect analysis, supplier corrective action, reject material, external audits, and internal audits.
Responsible for Process Control audits, Supplier Chain audits, ISO and other Agency audits.
Upper level tools used were daily Gemba walks, accountability meetings, customer focus and performance reviews on all value streams.
Hands on training completed of standard work and quality tools, gages, visuals, attribute tests and quality stations. 5S training and Poka-Yoke training completed and implemented in cells.
Management responsibilities have included Quality Engineers, Quality Inspectors, Gauge Lab Personnel, Foundry Maintenance Department, Foundry Supervision and Foundry Operators, Production Supervision, Value Stream Leaders and Production Operators in machining, injection molding, chrome plating, extruded hose and connectors, and assembly operations.
Responsibilities include OSHA and EPA compliance, worker’s compensation, and risk management for multi-location manufacturing and warehouse facilities.
Responsible for the technical writing, implementation, training and sustainability of all Safety and Environmental Programs to include Blood Borne Pathogen Control, Cadmium Compliance, Confined Space Entry, Crane Hoist and Below the Hook, Department Inspections Program, Electrical Safety Emergency Action and RCRA Contingency, Fall Protection, Hazard Communication, Hearing Conservation, Lead Compliance, Lockout/ Tag out, New Employee Orientation, Contractor Safety, Personal Protective Equipment, Powered Industrial Truck, Respiratory Protection, Machine Guarding, Accident Investigation and Reporting, Welding, Cutting and Brazing, DOT Security and Hazardous Waste Management.
Experienced in completing Job Safety Analysis (JSA) assessments. Implemented and trained Ergonomic Teams for manufacturing process improvements. Sustained a Value Stream Inspection Program and the Dupont Stop Program. Daily Gemba Walks are performed with cross-functional positions. Sustained a 5S Program and Lean Manufacturing Standard work Program. Responsibilities include industrial Hygiene studies to include lead and cadmium testing, chromium testing, noise testing, ventilation checks, and electrical checks, VOC emissions, hearing tests, respiratory fit tests and confined space atmosphere testing.
Responsibilities include statistical reporting of Lost Work Day Rates, OSHA Recordable Rates, DART Rates, Dupont Stop Audit Results and Injury Analysis. Additional reporting requirements include Section 13 of the Emergency Planning and Community Right-to Know Act (Form R), Tier ll EPCRA, Hazardous Waste Report, Monthly Tier ll Storm Water report and monitoring results, City Waste water Discharge monitoring and reports, and DOT reporting.
Responsibilities include the implementation and training of medical and chemical spill first responders and maintain first aid area and equipment, maintain spill response equipment.
Experienced with working with DHEC, DHNER, DOL, EPA, OSHA and DOT.
Management responsibilities have included Safety and Environmental Engineers, Nurses, Quality Engineers, Quality Inspectors, Gage Lab Personnel, Foundry Maintenance Department, Foundry Supervision and Foundry Operators, Production Supervision, Value Stream Leaders and Production Operators in machining, injection molding, chrome plating, extruded hose and connectors, and assembly operations.
1994-1997 IMO Industries, Warren Pumps - Warren, MA
Facilities Manager / Safety/ Environmental Manager
Facilities Manager for a large pump manufacturer with responsibilities for building and machine maintenance, preventive maintenance, power plant, plant layout, safety, health and environmental compliance.
1992-1994 J.D. Meagher, Inc. – Westborough, MA
Safety Director / Project Manager
Safety Manager, Project Manager and Sales Management for an environmental service company specializing in mobile and turn key projects in wastewater treatment and waste minimization. Responsibilities included the construction and management of wastewater facilities along the eastern seaboard to include all safety and environmental compliance, project budgets, job estimating and sales management.
1988-1992 Earth Resources Corporation - Ocoee, FL
Project Manager / Procurement Manager
Project Manager and Procurement Management for a full-service environmental firm. Projects include compressed gas remediation, soil remediation, landfill closure, tank removal, and ground water remediation.
1984-1988 Martin Marietta Aerospace - Ocala, FL
Senior Construction Buyer / Production Specialist
Procurement Management of construction contracts and contractors to include the construction of wastewater treatment plants, credit unions, manufacturing and office buildings. Managed all production planning and raw materials scheduling for the “ Lantrin” Air Force Program.
Education:
• Becker College - Teacher for the Environmental Management Certificate Program Continuing Education
• Becker College- Worcester, Ma. (Environmental Management)
• Kennedy-Western University (Safety Engineering)
• Southern Florida College
• State of North Carolina Water Pollution Control Operator - Physical/Chemical
• Certified Crane Inspector; Crane Institute of America
• OSHA Instructor for Coarse 500 and 501; OSHA Institute
• 40 - hour OSHA Hazwoper certified training; RCRA 40 CFR 265.16 certified
• Machine Guarding and Lockout Tagout certified training OSHA and Safety Council
• 49 CFR DOT Hazardous Materials Handling certified
• Advanced Hazardous Waste Compliance for Generators
• Air Quality Regulations OSHNC Occupational Safety and Health Course for General Industry
• Certified First Aid and CPR Trainer – American Red Cross
• North Carolina Grade Two Physical/ Chemical License
• The Quality College
• Waste Water Treatment Chemistry
• Cast Metals Institute Nonferrous Melting Technology & Practices
• Foundry Greensand Technology
• Occupational Safety and Health School NC DOL
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