Plant Manager

DEAN I. HONIG

**** **** ****** **** * West Bloomfield, MI 48324 * 248-***-**** * ******@***.***

EXECUTIVE PROFILE

General/Plant Manager

Assertive, results-focused professional offering 20+ years of success coordinating resources, providing strong leadership, and fostering team efforts to meet aggressive goals for productivity, efficiency, quality, and profitability. Astute strategist and creative problem solver with demonstrated abilities in implementing new systems/technologies and streamlining operations to reduce costs and downtime while ensuring customer satisfaction.

Selected Achievements

* Spearheaded continuous improvement measures at Accuma Corporation resulting in 35% cost savings more efficient manpower, 99% equipment utilization, achieve on time delivery, minimized inventory on hand by 66%, and enhanced profitability by 45%.

* Saved $1.1M, eliminated existing defects/mistakes, improved efficiency, reduced waste to less then 1%, achieved 3 PPM, improved equipment efficiency to 98%, expedited work cycles, and enabled overseas manufacturing to become profitable by setting up Lean Manufacturing systems internally and with subcontracted supplier in China and Taiwan.

* Significantly boosted profitability for Urgent Plastic Services by increasing sales, decreasing overhead expenses, implementing efficiency systems, and accelerating delivery and turnaround time. Doubled total annual profits to $5.5M by implementing a system to expedite the production and delivery of quality prototypes to a few weeks.

* Maximized profits, increased efficiency, and reduced manpower services for Bolton Conductive Systems LLC by introducing Lean Manufacturing throughout operations. Met all customer production schedules while improving quality, reducing excess inventory, and manufacturing products JIT.

* Implemented completed PPAP and PSO packages for Yazaki North America Inc. that were passed and approved by Ford, GM, Daimler Chrysler, Visteon, JCI, Lear, Bosch, Pioneer, Hella, Delphi, Siemens, and Teleflex. Achieved $7.6M in savings through proactive emphasis on Advanced Quality Planning (AQP). Delivered $6.2M in annual savings by achieving zero QRs as well as avoiding 8Ds and reworks. Capitalized $2.5M in annual savings by implementing cost-reduction negotiations and strategies.

Areas of Expertise

* Multi-Site Operations Management

* TQM

* Lean/Six Sigma Manufacturing

* Employee Relations

* Turnaround Management

* Kanban

* Process Engineering/Automation

* Labor Relations

* Financial Management/P&L

* 5-S

* Safety Regulations

* TPS/TPM

* Training/Coaching/Mentoring

* Kaizen

* Supply Chain Management

* TS-16949

CAREER TRACK

ACCUMA CORPORATION – injection molding manufacturing

Plant Manager 2008-2009

Held overall responsibility for daily operations, encompassing P&L, production control, quality, safety, sales, employee relations, regulatory compliance, and customer satisfaction.

* Introduced efficiency standards that reduced man-hours worked by 50% and cut overtime by 70%.

* Incorporated Six Sigma, 5S, Lean concepts, and introduced Kaizen.

* Introduced automotive industry processes and manufacturing systems to achieve Six Sigma standards

* Eliminated waste by decreasing mistakes and defects.

URGENT PLASTIC SERVICES – designs and manufactures injection molding, blow molding, stamping, and casting for various industries

General Manager 2005-2007

Oversaw the operations, engineering, CAD, quality/warranty, injection molding, casting, stamping, CNC, laser, EDM, shipping, maintenance, production, human resources, and purchasing functions for an ISO compliant company with 185 employees. Held sole P&L responsibility.

* Introduced Lean Manufacturing, TPS, 5S, Six Sigma, and JIT systems; continually improved their efficiency.

* Implemented a “fool proof” system that simplified the production process from inception to completion.

* Cut parts delivery time by 50% by keeping machining work in-house rather than outsourcing it.

* Elevated customer satisfaction by providing quality parts on time and at competitive prices.

* Trimmed man-hours by championing a proactive approach in all departments.

* Implemented “fool proof” manufacturing systems at production facilities in China and Taiwan.

* Eliminated defects, reworks, and airfreight costs by improving assembly line efficiency.

BOLTON CONDUCTIVE SYSTEMS LLC – designs and manufactures electrical/electronics components, wire harnesses, and instrumentations for the automotive, non-automotive, marine, aftermarket, truck, bus, RV, and industrial markets

Plant Manager 2003-2005

Supervised direct reports in engineering, quality/warranty, human resources, information systems, production, purchasing, production control, costing, paint, inventory control, GMSPO, and shipping within a QS-9000 facility with 265 employees. Worked with plastics from inception to final production.

* Minimized defects and saved ~$2.8M by implementing Six Sigma.

* Drove business growth by integrating and relocating three group facilities into a single major operation at one site.

* Instituted cost-saving systems for new product and “fool proof” Lean Manufacturing.

* Planned, organized, and executed multi-scale manufacturing projects on time and within budget.

YAZAKI NORTH AMERICA INC. – designs and manufactures injection molding for electrical/electronics components, wire harnesses, cables, modules, connectors, and instrumentations for the automotive and non-automotive industries 1989-2003

Program Manager 2000-2003

Managed design, CAD, engineering, sales, purchasing, quality, warranty, manufacturing, production control, and packaging for a QS-9000 compliant company with 120,000 employees worldwide. Spearheaded the launch of multiple programs and extended business contacts for multiple car lines. Interacted with affiliates and suppliers to build interior plastic trim components. Monitored program efficiency with a Microsoft Project based APQP time plan.

* Introduced Six Sigma and Lean Manufacturing to the production of GM Cadillac lines.

* Directed a supplier in establishing a major new wire harness production operation.

* Increased customer satisfaction/loyalty by setting up a parts and service system between the company and GM.

Quality/Warranty Manager, US; QA/Office Manager, Mexico Ford/GM Business Unit 1997-2000

Functioned as the sole Yazaki representative in Mexico; maintained multiple administration processes for the Mexico office complex, including full contract negotiation, payroll, and accounts payable. Monitored affiliates and suppliers in producing a variety of commodities, including plastics, metals, and wiring. Led/participated in department meetings and customer presentations. Supervised multi-production engineering teams.

* Set up an overseas assembly plant (China) utilizing Lean Manufacturing and achieved Six Sigma.

* Orchestrated ongoing quality improvement to ensure low PPMs and high quality product.

* Coordinated and directed QS-9000 implementation and compliance procedures.

* Designed and instituted functional job training programs and seminars to achieve zero QRs in other plants.

Program Manager/Quality Resident Engineer 1989-1997

Directed wire harness integration at Ford Motor Co. Lorain Assembly Plant, Lear Seating, and Cleveland Engine.

* Boosted profitability by continually improving the efficiency of Lean and JIT manufacturing processes.

* Mentored suppliers to meet Six Sigma and Lean Manufacturing goals.

EDUCATION

Master’s Degree in Electrical Engineering (In Progress), Cleveland State University

Bachelor of Business Administration in Marketing/Industrial Engineering, Cleveland State University

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