Paul Fluty Open to global relocation & extensive travel | e1creg@r.postjobfree.com | 303-***-****

Director of Operations | Offshore Manufacturing | Supply Chain Management

Innovative, process-focused executive problem solver who leads production operations to new levels of excellence.

10+ years of executive leadership results through business acumen, leadership skills, and multi-disciplinary engineering skills, driving productivity, safety, quality, and cost-efficiency in complex, build-to-order products in a vertically integrated organization.

Empowering leader who builds strong relationships, sets clear goals, and fosters accountability and collaboration. Driven to lead world-class Lean organizations to new levels of excellence.

Expertise in supply chain management: production forecasting; direct and indirect procurement, as well as purchasing of capital equipment, software & services; asset management and inventory control; and global distribution of finished goods. Versed in implementation and utilization of SAP and JD Edwards ERP/MRP systems. Win-win, data-driven negotiator.

Earned a reputation for sound business decision-making, leveraging analytical and fiscal management skills, developing budgets for capital expansion of operations, plant expansion, production equipment purchases, and production facilities.

Experience

LEXMARK INTERNATIONAL, INC. – Cebu, Philippines 2005 - 2011

Printing and imaging products, software, solutions, and services that help customers to print less and save more. Cebu’s 24/7 manufacturing operations produce $1B in inkjet printer consumables revenue with a staff of 2000.

GM & Director of Operations, Asia Inkjet Supplies | President & CEO, Lexmark International (Philippines), Inc.

Promoted to lead expansion and continuous improvement of established offshore manufacturing operations which grew to $1 billion in annual revenues. Reported to Global Director of Supplies in Switzerland and VP of Inkjet Supplies at U.S. HQ.

Directed a senior management team of 7 (HR, Finance & Accounting, Supply Chain, Operations, Engineering, Quality, EH&S, Continuous Improvement, Facilities, IT / Technical Training accountability for total plant staff of 1400 to 2400.

Developed and executed 24/7 production schedules to meet variable global demand for 20+ product families and hundreds of configurations of inkjet printer consumables. Delivered product on schedule with optimum quality and competitive cost.

Recognized for engaging a multicultural workforce through clear, two-way communication of goals, processes, and deliverables. Optimized workforce morale during periods of growth, reductions in force, and major changes to processes and procedures.

SUPPLY CHAIN:

Oversaw sourcing, procurement, and global logistics to assure a robust, cost-effective supply of raw materials (electronics components, flexible circuits, semiconductors, bottles, plastics, foams, inks, and chemicals) with annual spend of $200MM -$400MM. Controlled capital equipment spend of $20 million per year.

Recognized for improving inventory turns by 50%. Improved value-add ratio of cycle time from 3% to 10% for many products.

Led acquisition of capital equipment from existing operations, as well as, from Asian suppliers for a global automation initiative.

PROCESS IMPROVEMENT | QUALITY:

Directed comprehensive implementation of Lean Manufacturing and DMAIC Six Sigma process improvements with 100s of completed projects annually, including 200+ successful projects in 2010.

Instrumental in achievement of Integrated Management System certification for ISO 9001, 14001, and 18001.

Drove corporate compliance to environmental regulations, earning recognition from PEZA.

Improved KPIs to 99% on-time delivery to distribution and 99.5% user quality while reducing costs of goods sold by 7-8%.

PRODUCTIVITY:

Established flexible, high-volume and customized production operations with weekly delivery compliance > 99% while maintaining approximately 10 days of total inventory.

Expanded productivity per employee by 55% through process improvement and production uptime. Increased production capability by more than 150% to meet global demand.

Directed multiple IT implementation programs, including implementation of SAP ERP/MRP system, and upgrading from J.D. Edwards. Supported ongoing product security enhancements, and intellectual property protection.

ENVIRONMENTAL HEALTH & SAFETY | CORPORATE RESPONSIBILITY:

Outstanding safety performance including one period of 988 consecutive days without a lost-work-time incident (Award from Department of Environment & Natural Resources).

Earned National Hall of Fame Recognition (3 annual awards) from Philippines Economic Zone Authority (PEZA) for standout programs with both EH&S and Corporate Social Responsibility.

COST REDUCTIONS:

Improved yields, reduced raw material costs, and improved productivity. In years 2, 3, 4, and 5, credited with contributing up to $2 million per year to profitability, primarily by improving yields through Six Sigma projects.

Achieved, by second year, Cebu operations distinction as Lexmark’s least-cost producer for all products.

LEXMARK INTERNATIONAL, INC.- Boulder, CO 2001 – 2005

R&D and manufacturing for laser printer consumables supporting $2B in revenue.

Director, Site Technical Services

Promoted to lead a Technical Services team of 40: PhDs in Materials Analysis Lab, Supplies Functional Test Lab, Supply Chain / Purchasing, IT, and Supplies teams supporting site operations. Controlled an opex budget of $5M; capital budget of $1M.

PURCHASING | SUPPLY CHAIN: Accountable for supplier relations including all purchasing negotiations with adherence to corporate purchasing guidelines. Provided support and guidance to the engineering teams for identification and work with suppliers for Boulder’s R&D and manufacturing operations. Supply / Demand planning, engineering support, and supply chain execution for acquisition supplies.

INFORMATION TECHNOLOGY:

Responsible for planning and delivering IT services for site and extended operations. Participated in establishment of technical objectives, work plans, schedules, and cost objectives relative to business requirements. Ensured that the Boulder IT strategy and implementation was consistent with corporate strategy while also meeting needs of both Boulder R&D and manufacturing.

MATERIAL ANALYSIS | FUNCTIONAL TEST LABS:

Provided chemical / physical material analyses and functional testing of toners, photoconductors, and EP systems for operations support particularly in regards to problem solving and improved technological performance. Earlier roles with IBM and its spin-off, Lexmark: Sr. Engineer / Manager, Operations Manager, Site Purchasing, Operations Management for Facilities, Maintenance, Acquisition Engineering, Logistics, IT; Operations Management for Toner, Developer, Fuser Roll Manufacturing; Associate Engineer and Jr. Engineer, R&D.

Education

GEORGIA INSTITUTE OF TECHNOLOGY - MS, Mechanical Engineering / Computer Integrated Manufacturing Systems Certificate

UNIVERSITY OF KENTUCKY – BS, Chemical Engineering

Industry Leadership

AMERICAN CHAMBER OF COMMERCE (Cebu Chapter)

Board of Directors (2005-2011) Vice President (2006 – 2007); President (2008 – 2009); Ex-officio (2010)

MACTAN ECONOMIC PROCESSING ZONE CHAMBER OF EXPORTERS & MANUFACTURERS Vice President (2005 – 2007); President (2008 – 2011)

SEMICONDUCTOR AND ELECTRONICS INDUSTRY PHILIPPINES, INC. (SEIPI)

Board of Directors| Visayan representative to the Board (2008 – 2011)

Industry Expertise

Manufacturing processes (GMP/ISO-9000, JIT, Kan-Ban, etc.) and manufacturing equipment.

Materials Requirements Planning (MRP) | SAP.

“Lean” Manufacturing practices and principles.

Working knowledge of ISO 9001/14001/18001 quality standards.

ISO standards, SOP processes, and TPM techniques.

MRP processes including materials forecasting and procurement.

Project management tools and concepts.

Knowledge of safety, regulatory, and government agencies.

Recruit and manage Lean Product Development teams.

Apply Continuous Operations Improvement (COI)/ Lean concepts and techniques utilized throughout the plant.

Implement Total Productive Maintenance (TPM) System to maintain, repair, and improve plant machinery, equipment, and facilities.

Partner with Business Unit Leaders and Marketing Directors to evaluate new product concepts relative to manufacturing capabilities, in accordance with business unit external growth profit objectives.

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