MARK S. REBAR

607-***-**** gzc590@r.postjobfree.com

* **** *****, ******* ****, New York 14870

SUMMARY

Team oriented leader with a positive track record of continuous improvement using the learned

skills of Six Sigma, Lean Manufacturing, TQIP, 5S, in high output manufacturing environments.

Managing departments up to 250 hourly, supervisory and administrative staff, a sense of business

acumen in leadership, communication and manufacturing metrics that develop accountability,

efficiency and use of best practices to achieve customer satisfaction.

EXPERIENCE

TYOGA CONTAINER COMPANY, Tioga, PA 2010 to 2012

Carton and Dunnage material supplier to the packaging & shipping industries, sales of $25M / 75

non-union employees / 100K sq. ft. / operating 16/5 / producing 3M sq. ft. of corrugation/week.

Production Manager

Responsible for all production functions of manufacturing, warehouse and shipping

• Organized the warehouse, shipping and receiving departments, reducing cycle time

by one day.

• Created daily, weekly, monthly metrics allowing us to track employee performance,

give feedback and improve machine performance.

• Reduced setup time by 17% on our EMBA folder gluer using Kaizen event.

• Improved forecasting of manning needs by implementing two and five day reporting

as well as quantity of corrugation ordered.

THE MAPLE-VAIL BOOK MFG. GROUP, Binghamton, NY 1992 to 2009

Manufactured hard & paper-cover books. Sales $80M / 550 employees union and non-union /

300,000 sq.ft. / operating 24/5 / producing 500K to 1.2M books/week. Division closed 12/31/2009.

Bindery & QA Manager

Departmental leader with full responsibility for Safety, Quality, P&L performance, Efficiency,

Customer satisfaction and all Employee relations

• P&L performance included budget construction, implementation and tracking of an $8

million budget generating $4.5 million in contribution.

• Lead QA department to ensure manufacturing was meeting the needs and requirements of

external and internal customers. Used cross-functional team approach to improve

communication between QA and Bindery departments, credit this with improving QA

rejections 47%.

• Empowered employees to participate in productivity teams and suggest ways to improve.

$521,000 worth of cost savings were realized during the first 9 months of 2009 and $245,000

in 2008.

• Six Sigma Green Belt project produced $250,000 in additional sales revenue by improving

balance in materials as they were used in the manufacturing process.

• Directed yearly planning sessions used to organize all department head’s suggestions for

improvement and establish goals for budgeting process.

• Participated in 4 union contract negotiations, all achieved results desired by president of

Maple-Vail.

• Established TPM program to improve performance in the bindery department. Program included

mandatory PM, weekly cleaning, inspection of equipment and tracking system, monthly meeting with

Maintenance manager to review results and future plans.

• Mentored supervisors and team leaders in becoming effective leaders.

• Achieved 9% improvement on variable budget using Lean manufacturing techniques to

improve scheduling and manning performance during 2009.

Prep Manager

• Implemented and managed entire change in safety philosophy using the Dupont

STOP (Safety Training Observation Program) program. Reduced Worker's Compensation

claims $400,000 annually, monthly audits created by STOP teams to ensure compliance with

all safety and OSHA regulations. Achieved company goal of no accidents for one year.

• Published SOP manual defining a multitude of operations, simplified tasks, used to train

employees, establish quality & efficiency standards.

• Directed the move to electronic prepress. This change took on many issues; increased speed,

installation of million dollar equipment, raw material change, negotiating with union group

that part of the new process was not going to be union controlled and established electronic

prepress as a non-union group.

• Was instrumental in combining two departments from two locations, move equipment,

install methods for receiving/delivering electronic information & products to both facilities

without sacrificing customer expectations.

EDUCATION

Bachelor of Science in Business Administration

Gannon University, Erie, PA

CERTIFICATES

Six Sigma, Green Belt

Villanova University, Philadelphia, PA

Lean Manufacturing

Villanova University, Philadelphia, PA

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