Manufacturing / Engineering Manager
Resume:
GREGORY J. CLAYTON
Seabrook Texas 77586
Cell: 903-***-**** E Mail: **********@*****.***
SUMMARY
Manufacturing Operations / Engineering professional with a strong focus on continuous improvement. Particular expertise in:
LEAN implementation
Toyota / Ford Production System
Project Management
Change Coordination
Productivity / Cost Reduction
ACCOMPLISHMENTS
Six Sigma Green Belt certified through revival of idle automated equipment and 6 head labor savings.
Kaizen leader of all new LEAN assembly line utilizing Toyota Production System concepts.
Realized 50% scrap reduction through leadership mapping and DOE s.
Over 20 years of annual cost reductions of $500K or more through labor analysis projects and driving engineering changes.
PROFESSIONAL EXPERIENCE
TRANE / INGERSOL RAND Tyler TX 2006 Sept 2009
Industrial Engineering Manager
Managed staff of 6 engineers. Responsible for the operations and continuous improvement of the fabrication and assembly of residential outdoor air conditioning units and heat pumps. Processes include assembly testing brazing tube forming spine fin fabrication and automation. Area of responsibility included over 700 hourly employees in a million square foot factory.
Coordinate introduction of new models part changes and process changes.
Participate and led Kaizen events to reduce cost improve quality and for 5S.
Led projects to improve productivity and cost.
Led initiatives to improve safety performance including ergonomic tooling and workstation layout.
Controlled and monitored manpower throughout the plant.
Coordinated line balance changes and Rate changes.
Coordinated projects with outside suppliers to facilitate process improvements.
GUIDE CORPORATION Monroe LA 2002 2006
Operations Manager
Manage all injection molding and coating operations in the production of front-end lighting for General Motor s vehicles. Manage staff of 2 General Foreman 15 supervisors/technicians and over 300 hourly on 3 shifts.
Improved throughput on mold machines through machine optimization and reduction of scrap.
Launched new products on time with new equipment and aggressive ramp up.
Organized WIP areas to ease congestion reduce inventory and improve flow.
Incorporated Lean Manufacturing principles with increased use of small batches and point of use delivery.
Incorporated error proofing and quality principles in process such as torque shut off and pick lights.
Coached and coordinated scheduling principles to ensure on time delivery of WIP material.
Improved throughput of assembly by eliminating constraints through line balance or work station revision.
AIR SYSTEM COMPONENTS Terrell TX 2001 2002
Plant Manager
Directed all plant functions in the production of HVAC air system components for commercial buildings. Managed staff 24 salary and 260 hourly employees.
Improved plant performance from last place to first in cost on time delivery and safety.
Increased productivity through lean principles reducing manpower by 13% in three months.
Set up quality reviews to improve first time through percentage from 96 to 99%.
Eliminated budget overruns by implementing an online tracking system that was administered by management personnel and reviewed daily.
Trained staff and key hourly personnel in lean manufacturing principles.
FORD MOTOR COMPANY Claycomo MO 1988 2001
Superintendent 1995 2001
Managed the Final Assembly area in the production of major vehicle product. Led team of 8 salary and 300 hourly employees. Coordinated efforts of Engineering Q.C Maintenance and Materials personnel.
Increased productivity through labor reductions annually through labor reductions and line rate increases.
Managed launch of F150 Supercrew pickup truck on time and under budget.
Initiated and led special teams for exterior ornamentation interior trim electrical squeak and rattle wind and water and mechanisms.
Received J.D. Powers high customer satisfaction awards and took the lead among other Ford manufacturers for lowest warranty in several categories.
Organized and designed an online QR reporting system for supplier defects which promoted supplier accountability resulting in hundreds of thousands of dollars in revenue for the plant.
General Supervisor 1992 1995
Directed the production and quality of vehicles in the Final Assembly area. Absentee replacement for Supervisors and Superintendent. Managed team of 7 salary and 300 hourly employees.
Managed process changes and workstation layout.
Received special recognition for most efficient car line in North America.
Key leader for changeover from Ford Tempo to Ford Contour production on time and under budget.
Industrial Engineer Edison NJ 1988 1992
Coordinated work allocations time studies new model launches process audits methods improvements line balancing and manpower reductions.
Key team member in development of MPPS global computer process sheet software for Ford.
One of the first engineers to implement and train others in MODAPTS as a standard time study method. Educated union officials in the accuracy of MODAPTS which smoothed negotiations of disputes.
Key team member in the transition from car assembly to truck assembly.
BOEING Helicopter Division Philadelphia PA 1985 1988
Industrial Engineer
Scheduled and monitored progress in the production of the CH47D Chinook helicopter.
Received plant manager s employee of the month award for cost savings of over $1000 per helicopter.
EDUCATION
BS Industrial Engineering College of New Jersey Trenton NJ 1985
Contact this candidate