Plant Manager/Director of Operations

RICHARD GALLAGHER

**** ********* **** • Cumming, GA 30040 • 678-***-**** • (cell) 563-***-**** ********@*****.***

Qualifications for: LEAN MANUFACTURING OPERATIONS MANAGEMENT

P&L and Capital Budgeting experience in all manufacturing and support operations.

Engineering background, cross-functional team leadership, training and presentation skills.

Proficient in developing cost effective strategies for continual improvement of operations.

Skilled in developing staff, deploying workflow processes and new process technologies.

Technical skills in molding, extrusion, metal stamping/coating, plant layout, material flow.

Extensive experience in business planning, budgeting, strategy development/deployment.

Excellent skills in problem solving, systems analysis/engineering, data collection and analysis.

Recognized for interpersonal communications skills throughout all levels of the organization.

Hands-on management (union & non-union) in kaizen, lean manufacturing, 5S/Visual Factory.

CORPORATE CONTRIBUTIONS

Successful turn-around of Reaction Injection Molding plant, growing sales from $8.6mm to $14mm without adding to staffing levels, improving profitability approximately 1000%.

Achieved 7% sales growth, 20% profit increase and 150% improvement in on-time delivery during first year at Jet Rubber Company.

Developed structured cross-functional continual improvement initiatives at Johnson Rubber Company, generating $9.0mm reduction in operating expenses over an eight year period.

Directed operating department’s cross-functional activities at Johnson Rubber Company to achieve QS 9000 and ISO 14001 certifications and reduce workers compensation costs by 75%.

Implemented “day rate” pay structure to promote employee involvement, resulting in a 65% reduction of scrap at Johnson Rubber Company over a six-year period.

Developed and directed activities for the consolidation of a $10mm company (7 injection and 10 compression machines and support equipment) into operations at Johnson Rubber Company achieving an aggressive schedule under budget.

Led capital improvement projects on plant infrastructure and installed Maintenance PM program at Johnson Rubber Company achieving a 26% increase in equipment up time.

Engineered and directed activities for the installation, staffing and training of new process technologies (molded rubber/carpet floor mats) at Johnson Rubber Company, increasing revenues by $2.5mm.

Managed growth of injection molding business at Southland Industries, Inc. from “prototype” to production, grew over three years to $28mm in revenues with 24 injection molding machines.

PROFESSIONAL PROFILE

ROMEO RIM, Inc., Romeo, MI: General Manager May●2009-Jan●2011

P&L responsibility for operations of two Reaction Injection Molding facilities with 180+ hourly and 12 salaried staff. (Operations, maintenance, materials control, purchasing Continuous Improvement Engineering).

ROMEO RIM, Inc., DeWitt, IA: Plant Manager Oct●2006-April●2009

P&L responsibility for 35k sq. ft. Reaction Injection Molding plant, 8 salaried and 44 hourly.

RICHARD GALLAGHER

5335 Avonshire Lane • Cumming, GA 30040 • 678-***-**** • (cell) 563-***-**** ********@*****.***

JET RUBBER COMPANY, Rootstown, OH: President/General Manager Feb•2004-May•2005

Total P&L responsibility in directing activities of $5mm ESOP company manufacturing custom molded rubber products (injection, compression and transfer molding) for 450 industrial and commercial customers, with 7 salaried staff and 48 hourly. Scope of responsibilities included manufacturing, shipping/receiving, engineering (tooling, process, material), sales management, customer service, scheduling, accounting, MIS and facility maintenance. Established business planning process, monthly goals and objectives with appropriate metrics and re-organized staff to improve focus on delivery performance, scrap reduction and inventory reduction.

JOHNSON RUBBER COMPANY, Middlefield, OH: Director of Operations Oct•1991-Jan•2004

Managed the operation of two QS 9000, ISO 14001 facilities (one union, one non-union) with $52+mm in sales of molded and extruded rubber products, servicing 154+ customers in OEM Automotive (Ford, GM, Toyota), 1st Tier Automotive and industrial/commercial markets. Directed a staff of 54 salaried (10 direct reports) and 366 hourly to increase sales by 30% and profits 2000% over eight years. P&L responsibility for molding (injection, compression, transfer), extruding (conventional, hot-air, microwave), mixing (three #11D banburys, one #4 banbury), purchasing, maintenance, shipping/receiving, molded engineering (tooling & process), extruded engineering (tooling & process), process engineering (continuous improvement, cost reduction, training), safety and environmental compliance and energy management.

SOUTHLAND IND., INC., Va. Beach, VA: Director/Injection Molding Apr•1984-Sept•1991

Managed all aspects of an injection molding plant (union) start-up (tooling, prototype, equipment selection, staff hiring & training, facility preparation) and on-going production, serving OEM Automotive markets (Ford & Chrysler) with molded rubber engine sealing systems. Directed all plant operations in 40,000 sq. ft. facility with $28mm in sales.

3M COMPANY, St. Paul, MN: Senior Engineering Technologist Dec•1974-Apr•1984

Managed projects, designed equipment, tooling, facilities and processes in support of operations, manufacturing molded rubber High Voltage Underground Electrical devices and molded plastic wire termination devices.

ELASTIMOLD DIVISION, AMERACE-ESNA 1969-1974 F.H. MALONEY CO. 1966-1969

Employed in diverse capacities as Process Development Engineering Supervisor, Project Engineer, Mold Designer and Draftsman.

EDUCATION

UNIVERSITY OF HOUSTON: Bachelor of Applied Science, Mechanical Technology 1969

FORMAL TRAINING: Time Based Management • 5S/Visual Factory AMA Business Process Re-Engineering • 24/7 Operations Scheduling

SKILLS

MS Office (Word, Excel, Power Point) • Intermediate 5S/Visual Factory • Expert

Toyota Production System • Advanced Kaizen Work Shops • Advanced Kanban Inventory • Intermediate Process Design/Flow • Expert

Six Sigma • Working Knowledge Change Management • Expert

ISO 9000:2000 Auditor • Beginner ISO 14001 • Intermediate Smart Draw 7 • Intermediate Licensed REALTOR • State of Ohio

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