JOHN T. WILLIAMS
OPERATIONS / PLANT MANAGER / SENIOR STAFF ENGINEER
Plant Management / Budgeting / Material Handling Design / Environmental /
System Controls / Lean Manufacturing / Total Quality Management / AutoCAD /
Cost Estimation / Continuous Process Improvements / Vendor Negotiations
I manage and control plant operations using modernize operational techniques, analyzing systems, and processes, to eliminate redundancies, and cut costs. I optimize manufacturing operations and cost with improvements to quality and outputs, while reducing losses and improving costs.
With a proven record of building strong customer relationships, I have consistently devised winning methods to boost production and enhance throughput on time and under budget. In brief, my key strengths include:
• Driving standards, quality and plant process improvements
• Devising successful strategies to streamline complex operations
• Delivering projects from concept to completion on time and below cost
• Perform TQM, Six Sigma, and Lean analysis to develop products specification requirements.
• Develop specifications and SOP’s for the continual consistencies of products.
• Managing subcontractors, vendors, engineering, and design teams during installation / start-ups
• Comprehensive understanding of design engineering, manufacturing, and production methods
I have the ability to analyze situations rapidly and simplify complex problems. I am skilled at finding new approaches and alternatives to get the job done and exceed expectations. Personable and good natured, I have strong communication skills that allow me to build exceptional business, sales, and customer relationships.
CAREER HISTORY & ACCOMPLISHMENTS
Plant Manager, Mangum Brick Co.
I report directly to the CEO. I am in charge of retooling a small operation, producing specialty products for the Southwest OK and North Texas markets. Proposed a pulse firing system for the kiln which the company received a FDA, energy reduction grant.
Senior Staff Engineer, Lawrenceville Brick, 2005 – 2010, Lawrenceville, VA.
I developed and engineered a Landfill Gas project to replace the need for natural gas. This would cut cost at current prices by minimum of $600k per year. Redesigned the Sample Room layout with AutoCAD and improved the overall flow of this process, and over saw the construction of this department. After six month of operations, I took this operation on with a three month backlog and numerous wrong shipments and in two months we were at same week delivery. Using proven methodology we proceeded to next day shipments on most items.
I created a “Thin Brick” product line. Using existing equipment and personnel developed a system to produce 2,000 units per day, with no disruption in samples. Used Green engineering, whenever possible, by recycling the water for the Sample Master saw that uses 5 gallon/minute through a reservoir system.
Plant Manager, Hanson Brick, 2003 - 2005, Elgin, TX. A global manufacturer of bricks, roofing tiles, concrete pipes and aggregates.
I took on multiple quality issues from the start. Using 6 Sigma and Lean methodologies, eliminated most of these issues with employee buy in. Lead management teams, who analyzed problems, created SOP, quality control procedures, and witnessed the overall quality, turn around.
• Directed analysis, design, and elimination of process bottle necks. Seized opportunity to identify, develop, and improve plant processes with reworking of operational controls, retrofitting improved tooling for improved process flow. Managed several capital projects to increase production rates.
• Managed and provided detailed technical support for a six million dollar grinding process from concept to commissioning. This included project definition, feasibility studies, process technology, reduction in labor, and better particle size control.
• Led the retrofitting and redesign of a 1956 Swindell Dressler Plant. Redesigned the firing controls on the kilns to reduce fuel consumption by 12%. Redesigned the sand seals in the kiln for minimum air infiltration. Responsible for the integration of the new grinding room and support equipment.
Assistant Plant Manager, Plant Manager, VP of Manufacturing, Jenkins Brick Co., 1988 – 2003, Montgomery, AL. A manufacturer of brick and distributor of building materials. Reported directly to the CEO.
• Accountable for all operations pertaining to brick production, including quality, labor, budgets, raw materials, plant upkeep, preventive maintenance, continual improvements, customer relations and satisfaction, and product development.. Responsible for the analysis and redesign of the landfill gas system. This improved the A grade quality by 8% or $260k per year. Designed and over saw construction of a new grinding facility to enhance raw material consistency and eliminate rejects.
• Led team to completely re-engineer manufacturing equipment and processes. Responsible for increasing production from 26 million units / year to 50 million units/ year, by evaluating and recommending major expenditures to retrofit the production processes. Delivered on time and on budget, and increased production beyond expectations. Implemented safety requirements during all phases, developed contingency plans between design and commissioning stages, instrumental in coordinating two teams effort to successfully achieve the desired time frame. Provided reports to company owner and offered support and troubleshooting assistance to system engineers, team leaders, and maintenance.
Earlier Career: Plant Manager, 1978 – 1988. Over (4) different manufacturing facilities, developing continuous process improvements, cost reductions, excellent safety programs, good customer/vendor relationships, good environmental practices, and good labor relations.
• Slashed operational costs and increased quality using proven process control procedures. Helped define all quality standards and implemented controls to maintain them. Developed new products and processes to keep up with current trends in the industry and customer needs.
• Secured capital expenditure for major rework and expansions at all facilities. Modernized processes to maximized outputs and increase savings. Seized the opportunities to promote quality and safety as a working standard. Set the example.
EDUCATION / TRAINING / PERSONAL
East Mississippi Community College: Associates of Arts
Auburn University: AutoCAD
Tennessee Associates - Managing for Consistency
Clemson University - Brick Manufacturing Short Course
Software Experience: Advance knowledge of Microsoft Word, Excel, PowerPoint, and AutoCAD.
Also knowledge of Allen Bradley PLC’s, SEW VFD’s and servo drives. JDE, ERP.