Plant/Operations Manager

Michael W. McClure

*** ********* **** • Oswego, Illinois 60543 • Telephone: 630-***-**** • *****@*******.***

Strategic, senior operations/plant management professional with a progressive career. Expertise in senior operations and business leadership, production management, inventory management, distribution, logistics, quality control, organizational re-engineering, headcount reductions, supply chain management, IT optimization and integrations and capital planning.

Proven success in implementing new procedures to reduce costs and return rates, while increasing efficiency and margins: consistent success in reducing operating and labor costs, while increasing production and compliance. Demonstrated expertise in strategic operational, budget, capital and asset planning, as well as cost reductions, organizational re-engineering, performance-based accountability, continuous improvement and labor control.

Certified Lean Expert ... Bachelor of Science, Industrial Engineering

CORE COMPETENCIES:

Leadership & Motivation

Manufacturing Methods

Process/Continuous Improvements

ERP Implementations

Lean, Kanban, Kaizen, 5S, TQM,

GMP Implementations

ISO Certifications

Budgeting & P&L Management

Contract Negotiations

PROFESSIONAL AMERICAN BOXBOARD, LLC, Bedford Park, Illinois

Start up brown box converting plant (opened in 2007); division of Batavia Container, Inc.

EXPERIENCE:

Plant Manager 2008 to 2009

Hired to increase efficiency targeting profit and capturing market share; added third shift and delivered substantial production, maintenance and building improvements. Designed and implemented engineering and process improvements plant-wide with management control over production, quality and compliance, scheduling, demand planning, maintenance, logistics, purchasing and quality control. Maintained constant attention on reducing operating costs and machine downtime, as well as increasing overall operational efficiency and quality.

Summary of Accomplishments:

• Orchestrated plant-wide reorganization: developed and implemented new processes, standards and quality improvements to drive plant efficiencies and success; results:

- Improved on-time shipping from 85% to 96% consistently;

- Increased output to meet demand;

- Increased OEE (Overall Equipment Effectiveness) an average of 10% monthly;

- Reduced customer rejected orders to less than .01%;

- Decreased maintenance downtime by 15% to less than 5%.

• Renegotiated vendor contracts and initiated weekly vendor meetings to drive quality.

DESIGNED STAIRS, INC., Sandwich, Illinois

Closely-held, $20 million custom/production residential stair designer and manufacturer.

EXPERIENCE:

Manufacturing Manager 2000 to 2008

Charged with driving aggressive improvements across supply chain, manufacturing and scheduling to reduce operating costs and increase plant-wide efficiency during rapid corporate growth. Led all plant operations, including MIS (ERP), budgets, inventory, supply chain management, demand planning, purchasing, safety, environmental, capital improvements, quality and Lean manufacturing. Successfully guided company through record revenue and growth, as well as kept company profitable during rapid industry decline.

Summary of Accomplishments:

• Orchestrated launch of new technology, Lean, continuous improvement and staff accountability initiatives, creating a top performing, professional operation with refined data and metrics. Delivered strategic, aggressive and sustainable improvements across operations, purchasing, vendor management, supply chain, inventory and maintenance:

- Implemented Lean programs reducing total manufacturing cost by 21%;

- Increased inventory turn from 8.04 to 12.94;

- Improved product quality by 37% increasing overall quality rating to 98.5%;

- Reduced raw material costs by 10% through vendor re-negotiations;

- Re-engineered supply chain processes improving on-time shipping from 82% to 99%+;

- Reduced inventory required to support sales by 24% from 2005-2008.

• Lean Programs:

- Created work cells increasing productivity (three associates produced production of 10).

- Utilized Focused Factories to eliminated non-value added processes reducing total manufacturing cycle from three weeks to less than one day;

- Implemented small production lots, weekly goals and formal job training delivering a throughput increase of more than 50%;

- Converted waste materials into usable product adding $250,000 in annual revenue.

• Implemented daily material count processes eliminating annual physical counts, while delivering year end inventory within 1% of ERP Stock Status report.

• Developed and launched new inventory management programs allowed a reduction in inventory required to support sales by 24% from 2005-2008.

• Steering team leader for the planning, sourcing, selection and implementation of two ERP systems (completed second migration in three months). Expanded utilization of Electronic Documentation to drive efficiency and accuracy throughout supply chain.

LFC, INC. (Division of Filtration Group, Inc.), Aurora, Illinois

Privately held manufacturer of HEPA filters for consumer vacuum cleaner markets. A $10 million division with high profit margin.

EXPERIENCE:

Plant Manager 1997 to 1999

Accountable for planning and directing all manufacturing, customer service, purchasing and engineering of this high margin HEPA filter manufacturer. Key interface for major customers, including Honeywell, Duracraft and Electrolux.

Summary of Accomplishments:

• Spearheaded implementation of ISO 9001 certification without consultants; facilitated manufacturing of five new product families with two new technologies.

• Directed launch of new ERP system from sourcing through post implementation support.

• Engineered a conversion for filter pleating line allowing immediate switching of line between string pleat separators to hot melt pleat separators.

• Led capital planning and start up of five new production lines.

CONSTRUCTION FASTENERS, INC., Reading, Pennsylvania

Privately held $62 million manufacturer of steel fasteners.

EXPERIENCE:

Plant Manager (Fastener Division) 1993 to 1997

Manufacturing Engineer Manager 1993 to 1997

Facilitated company growth from $42 million to $62 million in four years. Managed all plant operations while creating and executing engineering, productivity and efficiency across critical manufacturing. Tracked, compiled and analyzed statistical results. Conducted equipment and work time studies; developed capital improvement justifications and set individual line goals.

Summary of Accomplishments:

• Reduced manufacturing headcount by 46% and work in-progress by 90% through Lean strategies and employee engagement.

• Championed Dale Carnegie team building process, which yielded more than $500,000 in cost savings identified by line employees.

• Reduced waste in machine set ups: increased products by 300%.

• Increased quality by 57%; increased machine uptime by 52%.

EDUCATION: BRADLEY UNIVERSITY, Peoria, Illinois

Bachelor of Science, Industrial Engineering

TRAINING: Certified Lean Expert; completed numerous courses in 5S, Lean Manufacturing, OSHA safety, staff and operations management, and computer operation.

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