Manufacturing Lean manager

EDWARD J. SPENCE JR.

** *********** ******, ******, ** 01851 (C) 978-***-**** (H) 978-***-**** *********@*****.***

OPERATIONS MANAGER

Cross-Functional Leadership · Quality Performance · Productivity Improvement

Results & detailed oriented, self-motivated manufacturing leader with over 10 years of experience leading diverse teams to new levels of success in a variety of highly competitive environments. Strong management qualifications in strategic planning, manufacturing, business unit development, lean manufacturing implementation, product and project management and system engineering strategies. Participative leadership style with excellent skills in cross-functional team building, quality performance and productivity improvement.

SKILLS

Lean Manufacturing / Six Sigma/ DMAIC

Theory of Constraint/Kaizen Events/Kanban/5S/Andon Lights

Process Monitoring/Process Mapping/ Value Steam Mapping

Problem Analysis & Resolution.

Plastic Manufacturing/ Extrusion and Injection molding

Team Leadership / Building

Program / Project Planning & Execution

Change Management/ Continuous Improvement

Budget Development and Management

GMP regulations/ Quality System Management/SPC

FDA and ISO Management

Client Relationships / Customer Service

Proficient in MS Excel/ Word/ PowerPoint and ERP systems

Product Development/Product Launch

Product Transfers/ In sourcing and Out sourcing

HIGHLIGHTS OF QUALIFICATIONS

Spearheaded change through setting positive benchmarks for the business unit, then developing a Lean culture that will react and succeed to a changing customer demand environment. Empowered team members to affect success.

Net result of $16.4 million annually in profits.

Created a vision for an organization that lacked a plan for the future. Implemented a system to monitor and guide the organization in achieving its goals. Over 800% annual financial improvement and additional growth in the business unit of 43%.

Led the implementation of Lean/ Six Sigma projects that would impact all business units, customer service and increase net profits. 68% reduction or $180 million in annual cost savings directly related to the projects.

Developed weekly safety audits that were conducted by a rotating team of Operators, Shift manager/Leads, Technicians and Engineers for issues in manufacturing practices, procedures, and policies improvements as needed. These were given as an update during a weekly shift meeting and were continuously updated and posted until the issues were resolved. Annual reportable incident rate reduced by 200% and the last 2 years with no reportable incidents.

Managed the out sourcing of two manufacturing business units to Mexico. The project required FDA filings, Quality controls, Document transfers and conversion, Purchasing and Planning impact and transfer of vendors. Process, equipment, packaging and sterilization validations. Extensive training was required for on boarding team of Engineers, Technicians, Managers and Operators. Inventory buffers were established for minimal impact to service and inventory cost. Developed a ramping up and ramping down system to limited the impact of both service and inventory cost during the transfer. Both projects finished on time and under budget with no impact on quality, service and cost.

Championed for business growth and stability. Proactive and strategically lobbied for research and development while finding the best avenues for growth within the business. Increases profitability, knowledge and skills of the site and workforce as well offered option for continuous growth in the future.

Researched and analyzed the business flow. Mapped out the processes using value stream mapping and process mapping. Created a system of management that would react to business needs with the use of Lean manufacturing, Six Sigma, Process Monitoring and the creation of a Manufacturing Dash Board. Consolidating equipment uses and best practices created the opportunity for increased quality levels, quicker responses to the customer, reduction in cost and addition growth potential. Yield improvement of 44%, a 42% capacity improvement, cost saving of $10.4 million annually and 3 new additional product lines.

PROFESSIONAL EXPERIENCE

EGGROCK , Littleton, MA 2009-Present

Operations Manager,

Direct Reports - 51 - 1 Shift Supervisors, 2 Mechanical Engineers, 1- Quality Engineer , 1 Warehouse Manager , 46 Operators

-Responsible for all financial requirements of the Operations. Established annual budgets, Capital investments, Labor and Material cost, P&L, COGS, Operating Profit and Expenses

-Developed employee talent pool to create high performing, self-reliant teams; encouraged team participation and tracked goal achievement.

-Responsible for communication and management of organizational objectives to the VP of Operation,

-Initiated an ongoing future business plan to augment unit’s knowledge and technology base, used as basis for future business acquisitions.

-Responsible for Manufacturing side of the development of new and existing products meeting all manufacturing standards.

-Implemented additional Lean Manufacturing principles and Six Sigma strategies, resulting in significant operational improvements and increases in capacity.

MEDTRONIC , Danvers, MA 1997 – 2008

Project Manager, 2007 - 2008

-Created and executed project work plans and revises as appropriate to meet changing needs and requirements. Set and managed Project expectations.

-Identified resources needed and assigned individual responsibilities. Set and managed project expectations. Managed the development of team by ensuring, when possible, that project tasks are in line with each team member’s career interests.

-Managed day-to-day operational aspects of a project and scope. Reviewed the status reports of team members and addresses issues as appropriate. Resolved and/or escalated issues in a timely fashion.

-Effectively applies our methodology and enforces project standards, to minimizes our exposure and risk on project. Reviewed status reports of team members and addresses issues as appropriate.

-Ensured project documents are complete, current, and stored appropriately. Regulatory, quality filings when needed.

-Managed project budget. Determined appropriate revenue recognition, ensured timely and accurate invoicing, and monitors receivables for project. Analyzed project profitability, revenue, margins, and utilization.

-Effectively communicated relevant project information to superiors, through engaging, informative, well-organized presentations. Understand how to communicate difficult/sensitive information tactfully.

-Built a knowledge base of each project's business, organization and objectives. Identified opportunities for improvement and makes constructive suggestions for change and managed the process of innovative change effectively.

Manufacturing Manager, 2005 - 2007

Direct Reports - 71 - 2 Shift Supervisors, 5 Engineers, 4 Technicians, 63 Operators

-Responsible for all financial requirements of the department. Established annual budgets, Capital investments, Labor and Material cost, P&L, COGS, Operating Profit and Expenses

-Led the analysis, the growth and the development of new production in excess of $15 million.

Supervised all aspects of transfer of various manufacturing processes from internal and external customers.

-Interfaced with customers to plan and develop procedures.

-Established critical partnerships with high-level industry leaders.

-Responsible for Manufacturing side of the development of new and existing products meeting all manufacturing standards. Partnered with the R&D department and Product Transfer teams to ensure all GMP requirements were satisfied before manufacturing start up.

-Responsible for communication and management of organizational objectives to the Directors of Operation, Quality and Supply Chain, peers and direct employees for both internal and external customers as well as compliance to GMP policies and regulations.

-Implemented additional Lean Manufacturing principles and Six Sigma strategies, resulting in significant operational improvements and increases in capacity.

-Supervisor of lean based, high capacity manufacturing of extruded processes.

-Leader of 3-person management team controlling a budget of $6 million.

-Revamped employee business practice and culture through positive team training and motivation.

-Initiated an ongoing future business plan to augment unit’s knowledge and technology base, used as basis for future business acquisitions.

Production Supervisor / Cell Coach, 2001 – 2005

Direct Reports - 38- 2 Technicians, 36 Operators

-Supervisory responsibility for technology, assembly, sub-assembly, manufacturing and packaging departments.

-Interacted with cross-functional groups and research & development teams to determine and direct quality improvements and maximize innovation.

-Optimized customer service through use of lean practices.

-Developed employee talent pool to create high performing, self-reliant teams; encouraged team participation and tracked goal achievement.

-Administered and oversaw contract manufacturing initiatives; monitored budget.

Manufacturing Technician, 1998 – 2001

-Supported daily manufacturing functions.

-Assisted engineering with new product development.

-Maintained proper inventory level to ensure no impact to production.

-Performed equipment maintenance, effectively planning around production and R&D schedules.

ADDITIONAL EXPERIENCE

Production Operator/ CR Bard 1996-1997

Carpenter/Construction, 1992-1996

Small Business Owner, 1992-1996

Restaurant Manager, Bartender, Cook, 1988-1994

Salesperson/Sears, 1985-1988

US Army Cook, 1983-1985

EDUCATION

Endicott College, Beverly, MA -Master of Business Administration, GPA 3.9, 2006-2008

Endicott College, Beverly, MA -Bachelor of Business Administration, GPA 3.9, 2002-2005

Wagner College, Staten Island, NY- Associates in Liberal Arts, GPA 2.7, 1985-1988

CERTIFICATIONS

Six Sigma Green Belt

Lean Enterprise

Six Sigma Process Improvement

Corporate Institute of Project Management

Theory of Constraints

Auditing for GMP Compliance

Problem Solving and Corrective Action Using 8D

OSHA Compliance

PERSONAL INFORMATION

Single, No Children

Non Home Owner- Open to relocation with ease

Hobbies- Restoring classic automobiles, Collector of sports memorabilia and autographs

Activities - Exercise, Weightlifting, Softball, Swimming and Travel

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