Manager Engineer

CLIFTON BARR

***** *******’s Valley Rd 276-***-****

Damascus, Virginia 24236

SUMMARY OF QUALIFICATIONS

Manager with successful experience in composite decking, textile manufacturing, apparel manufacturing, and distribution center environments. Strengths in initiating, developing, and directing process and systems enhancements to improve service levels and material utilization while reducing inventory levels and labor costs. Excellent planning, analytical, communication, and leadership skills.

Professional Experience

AVGOL NONWOVENS, , Mocksville, NC, December 2006-December 2009

Manager, Production Planning

* Manage production control and scheduling for the entire facility.

* Responsible for managing raw material and production supply functions for the facility.

* Responsible for managing shipping and warehouse functions for the facility.

NATIONAL TEXTILES, leading textile manufacturer servicing the apparel industry; previously owned by Sara Lee Knit Products, January 2003-December 2006

Manager, Production Planning, Eden, NC, June 2005-Present

* Manage production control and scheduling for the entire facility including receiving, knitting, automated greige cloth storage & retrieval, dyeing, finishing, cutting, compacting, and stretching.

* Evaluate orders from corporate planning and outside customers, and advise on the availability of production capacity at targeted deliveries

Manager, Production Planning, Greenwood, SC, January 2004-May 2005

* Manage production control and scheduling for the entire facility including receiving, knitting, automated greige cloth storage & retrieval, dyeing, finishing, cutting, compacting, and stretching.

* Evaluate orders from corporate planning and outside customers, and advise on the availability of production capacity at targeted deliveries.

* Direct a staff of 24 people consisting of two planning supervisors and a shipping supervisor as well as systems technicians, material utilization technicians, dye-house clerical staff, production expeditors, and knitting schedulers. Oversee equipment and process scheduling, schedule implementation, order tracking, and maintenance of production systems and automated scales.

* Devise strategies for reducing production throughput times, work-in-process, and waste, working collaboratively with the plant manager and production managers.

Accomplishments:

* Designed and implemented procedures for inventory control, line balancing, production scheduling, and work-in-process tracking while supporting production growth and increase in complexity from 850,000 pounds/week of jersey to 950,000 pounds/week of fleece and jersey.

* Improved service levels from the low 70s to 95+%.

* Reduced inventory from 3-4 days of inventory to 1.75 days of inventory.

* Lowered lead times from more than two weeks to less than one week.

* Reduced monthly material losses from $1 million to $15,000.

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Cutting, Finishing, and Shipping Manager, Eden, NC, January 2003-January 2004

* Directed 8 supervisors and 250 associates on four shifts responsible for manual and automated cutting, dry finishing, customs document preparation, and shipping.

* Trained supervisors to interpret labor reports and calculate staffing needs based on volume projections, which aligned labor with production orders and budgets.

Accomplishments:

* Reduced off quality from 5-6% to 3.57% by instituting procedures for machine set-up and critical checks as well as requiring operators to report machine and quality issues on a timely basis.

* Reduced labor variances from a negative 20 headcount to a positive 8 headcount.

* Initiated throughput measurements of each department, improving on-time delivery of lots executed in cutting, finishing, and shipping from 88% to 97%.

JONES APPAREL GROUP, apparel designer, marketer, and distributor, Feb. 2002-Dec. 2002

Industrial Engineering Manager, South Hill, VA

* Led distribution center projects, working with managers to align systems with center requirements as well as training managers and associates on new procedures and work processes.

Accomplishments:

* Implemented a PKMS warehouse management system to include defining inventory tracking points and instituting methods for capturing transactional data using scanners and RF devices.

* Implemented a Kronos time and attendance system that tracked labor for major operations and enabled development of labor standard as well as reporting of actual vs. labor costs

* Managed the installation of an inbound conveyor and palletizing system as well as a GOH sortation system, reducing headcount by 20+ while maintaining and improving production levels.

* Expanded the distribution center from 700,000 to one million sq. ft., enabling the company to close another facility for significant cost savings.

* Improved on-time delivery from the high 80s to 95+%.

NATIONAL TEXTILES, March 1993-October 2001

Manufacturing Services Manager, Eden, NC, May 2000-October 2001

* Managed production planning, industrial engineering, and inventory control-production tracking systems for the Eden facility, which produced 1.6 million pounds/week of fabric.

Accomplishments:

* Introduced incentive pay in the cutting operation, reducing labor costs by 10%.

* Led the review and adjustment of labor standards in knitting, reducing labor costs by 15%.

* Instituted procedures to update standards based on process and equipment changes.

Manager, Production Planning, Eden, NC, July 1994-May 2000

* Managed production scheduling and inventory control activities. Devised and implemented strategies for performance improvement in collaboration with management team members.

Accomplishments:

* Initiated and implemented operational controls in the batching area, reducing monthly material losses from 20,000 pounds to less than 1,000 pounds.

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* Reduced throughput from three weeks to one week (order receipt to cutting and kitting), and improved on-time deliveries from the low 80s to 98-99%.

* Reduced inventories from 10 days to 3-4 days of inventory during a period of monthly volume growth from one million pounds to 1.6 million pounds.

Senior Staff Industrial Engineer, Winston-Salem, NC, March 1993-July 1994

* Implemented multi-plant cost reduction projects that included balancing the cutting area to improve material utilization, achieving cost savings of more than $360,000/year.

SARA LEE KNIT PRODUCTS, January 1988-March 1993

Senior Plant Industrial Engineer, Martinsville, VA, January 1992-March 1993

* Performed engineering duties for two knitting facilities that included installing new standards and payroll systems, improving work methods, justifying capital projects, and explaining variances.

* Contributed to a 35% reduction in direct labor costs through the implementation of Vanguard knitting machines as well as the introduction of new work methods and incentive pay rates.

Industrial Engineer, Martinsville, VA, December 1988-January 1992

* Provided engineering services to several sewing plants in the areas of floor layouts, work methods, equipment evaluations, and labor budgeting. Assisted in setting up standards and payroll systems for the stocking and picking operations within the distribution center.

WRANGLER, Lincolnton, NC, January 1988-November 1988

Industrial Engineer

* Performed industrial engineering duties at the Wrangler distribution center.

* Revised payroll procedures, improving efficiency and accuracy.

EDUCATION

Bachelor of Science, Industrial Engineering and Operations Research, 1987

VIRGINIA POLYTECHNIC INSTITUTE AND STATE UNIVERSITY, Blacksburg, VA

* GPA: 3.59/4.0. Gilbert and Lucille Seay Scholarship. Academic All-American Award.

PROFESSIONAL ACTIVITIES

Society of Manufacturing Engineers; Institute of Industrial Engineers; Association of Textile Industrial Engineers. Pursuing APICS CPIM Certification.

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