Lean Plant Manager

DOUGLAS E. COLLIER

***** ***** **. ****** ****, MI 48135

734-***-**** ********@*****.***

SUMMARY

Machines utilized:

• Cincinnati Milacron, Davis Standard, Engel, HPM, Newbury, Toshiba, Van Dorn, 50 -3300 tons.

• Pad print, Hot Stamp, Sonic Weld, Hot Plate Welding, Heat Stake, Clip Insertion.

Process Knowledge:

• Injection, Extrusion, Vacuum Forming

Materials utilized:

• Acetal, ABS, ASA, Acrylic, Butyrate, HDPE, Nylon 6, 6/6,666 filled and unfilled, Polypropylene, Polycarbonate (optical grade), Polystyrene (HIPS), Polyphenylene Sulfide, PVC flexible and ridged, PET, PBT, TPO, TPE

Automation Knowledge:

• Fanuc, Yushin, Motoman, Conair/Sepro, Engel

Products:

• Automotive, a/b/c/d pillars, assist grips, package trays, center consoles, scuff plates, speaker grills, door panels, deck board, high grade deck side trim, deck box/tire cover, rear fifth door, rear quarter panel, storage systems, seating systems, audio/video, door panel inserts, gearshift & park brake boots, soft top systems, sun visors, door handles, airbag systems, bumper support systems, fender and mudguard systems, door locking systems, paneling and railing systems, fuel tank components, cooling systems, fan shrouds, commercial motorize drainage housing and components, personal locator beacon systems, personal strobe/incandescent light, rescue whistle, search light, flash light, crew overboard systems, vhf survival radio, ship security alert system, search and rescue transponder and float free memory capsule

• Expertise in lean manufacturing (TPS), six sigma, team building, inventory management, scientific injection molding, and ISO9000 have led to my accomplishing the turnaround of two facilities, the Greenfield startup of two state-of-the-art facilities; and leading three plants through their quality certification.

EXPERIENCE

04/08 to 12/08, Plant Manager, Industrial Plastic Products, Miami Lakes, Fl (Company downsizing)

Electronic Industry OEM and tier one supplier with 125 employees/2shifts, 20 Injection Molding Machines (65 ton to 500 ton), 2 Extrusion lines, and Assembly

• Daily Accountability meeting- reviewed hot presses, scrap, efficiency, material issues, quality issues, and safety, followed up on critical issues

• Worked in conjunction with Product and Lean Manufacturing Teams to correct problems on manufacturing floor

• Tool Room responsibility

• Profit and Loss responsibility

Achievements:

• Implemented 5S program and created safety committee; reduced loss time injuries by 56%

• Implemented TPS and master scheduling; increased inventory turns from 221%

• Implemented SMED system; reduced change-over-time by 94 minutes

• Implemented six sigma and scientific molding; reduced PPM's by 4497

• Created W.A.S.T.E. (War Against Scrap Takes Everyone) Team, implemented lean manufacturing and increased profit margin by 8%; turn around company lose of $75K per month; profitable in 3 months

2002 to 04/08, Plant Manager, Avon Plastics, Rochester Hills, MI (financial instability)

Automotive tier one/two supplier, interior and exterior trim with 60 employees/2 shifts, 20 Injection Molding Machines (75 ton to 1500 ton)

• Daily Accountability meeting-scrap, efficiency, material issues, quality issues, and safety, follow up on critical issues

• Worked closely with Product Teams, Lean Manufacturing Teams to correct problems on manufacturing floor

• Reduced inventory by 40%

• Reduced inventory 40%, waste removal 30%, scrap 17%, overtime 70%

• Profit and Loss responsibility

Achievements:

• Implemented 5S program and created safety committee; loss time injuries 0 for 2005, 2006, and 2007

• Created W.A.S.T.E. Team, implemented lean manufacturing; reduced cost by 35%

• Implemented TPS and master scheduling; increased inventory turns by 1080%

• Implemented SMED system; reduced chang-over-time by 224 minutes

• QS9000 implementation, six sigma, scientific molding; reduced PPM's by 6616

1998 to 2002, General Manager, Mexican Industries, Detroit, MI (Company closed)

Automotive tier one supplier of interior and exterior trim with 450 employees/3 shifts, 56 Injection Molding machines (300 ton to 3300 ton), Vacuum Forming, Assembly and Paint

• Daily Accountability meeting- reviewed hot presses, scrap, efficiency, material issues, quality issues, and safety, followed up on critical issues

• Worked in conjunction with Product and Lean Manufacturing Teams to correct problems on manufacturing floor

• Leadership Development, Team Leader training programs and Global Measurable

• Reduced inventory 50%, Synchronous Management techniques for scheduling and receiving

• Reduced Total Cycle Time 6 days

• Reduced inventory 50%, staffing 60%, waste removal 30%, scrap 10% and overtime 70%

• Profit and Loss responsibility

Achievements:

• Implemented 5S program and created safety committee; loss time of injuries 0 for 2000 and 2001

• Created W.A.S.T.E. Team, implemented lean manufacturing; reduced cost by 45%

• Implemented TPS and master scheduling; increased inventory turns by 1036%

• Implemented SMED system; reduced change-over-time by 220 minutes

• QS9000 implementation, six sigma, scientific molding; reduced PPM's by 8504 and turn around lose $1million per month; break even in 3 months, profitable in 8 months

1992 to 1998, Plant Manager, Libralter Plastics, Sterling Heights, MI (Career advancement)

Automotive tier one/two supplier, interior and exterior trim with 400 employees/3 shifts, 32 Injection Molding (75 ton to 1500 ton) Assembly and Paint.

• Daily Accountability meeting- reviewed hot presses, scrap, efficiency, material issues, quality issues, and safety, followed up on critical issues.

• Worked closely with Product Teams, Lean Manufacturing Teams to correct problems on manufacturing floor

• Implemented QS9000

• Certification Audit

• Introduced Toyota Production System (TPS), Team concept; increased inventory turns by 454%

• Trained staff in Shingo SMED System; reduced change-over-time by 75 minutes

• Introduced Don Paulson Injection Molding, Toyota Production System

• Created W.A.S.T.E. Team, implemented lean manufacturing; cost reduced by 20%

EDUCATION

• 1990, BBA, Eastern Michigan University

• 1982, I A.D. (Tool Engineering), TT Technical Institute

TRAINING

• QS/ISO9000, MMTC, Ann Arbor MI

• QS9000 Internal Auditor, Perry Johnson, Southfield MI

• Seven Habits of Highly Effective People, MPPA, Sterling Heights MI

• OHSA Regulations, MPPA, Sterling Heights MI

• Basic First Aid & CPR, MPPA, Sterling Heights MI

• Toyota Production System, University of Dayton, Livonia MI

• Dale Carnegie Management Training, Ralph Nichols, Farmington Hills MI

• Team Building, Scott Fisher & Associates, Ann Arbor MI

• Inventory Management, Libralter Plastics, Walled Lake MI

• Lean Manufacturing, Libralter Plastics, Walled Lake MI

• Statistical Process Control, A.S.I., Dearborn MI

• Design of Experiment, A.S.I., Dearborn MI

• Eight Discipline Problem Solving, A.S.I., Dearborn MI

• Control Plans, FMEA, PFMEA, Key Plastics, Plymouth MI

• Industrial Supervision, Schoolcraft C.C., Livonia MI

• Share the Knowledge – Injection Molding, General Electric, Southfield MI

• Dr. Deming’s 14 Points of Light, American Motors, Clinton Twp. MI

• Tool Design and Repair, American Motors, Clinton Twp. MI

• Don Paulson Injection Molding Theory & Practice, American Motors, Clinton Twp. MI

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