Seasoned Production Supervisor / Manager for Packaging Industry
Resume:
D. PAUL DUTKA
Mississauga, On.
*.****.*****@*****.***
PROFILE
A Production Manager with over 20 years of progressive leadership experience in developing & leading teams within various manufacturing operations. A well organized, committed individual with proven strengths in productivity improvement, cost savings and waste reduction. Knowledgeable in providing training and maintaining compliance to OHSA, WHMIS, and ISO 9001 standards.
CAREER HISTORY
Industrial Containers ULC;
A division of BWAY Corporation Company, which designs and produces a comprehensive line of rigid metal and plastic containers.
PAIL LINE BUSINESS UNIT MANAGER JAN. 2009 – DEC. 2009
• Co-ordinated the activities of 60 employees over a 3 shift operation consisting of manufacturing, maintenance and shipping personnel.
• Successfully maintained the Plant’s compliance to Health & Safety policies and targets by motivating and leading by example.
• Provided effective problem solving assistance to the Line Mechanics ensuring that productivity goals and line speeds were met.
• Increased uptime to over 95% efficiency and increased production 25% by scheduling staff to continuously run the line, without any additional employees added to roster to manage breaks and relief periods.
• Prepared production reports and delivered daily updates to the Operations Team.
AFTERNOON SHIFT SUPERVISOR – PAIL LINE, COATING & LITHO, SHIPPING DEPARTMENTS 2008-2009
• Efficiently supervised the steel pail production line ensuring that order requirements were met.
• Verified the accuracy of BOM (bills of materials) structures in SAP and made improvement recommendations.
• Effectively provided technical support to the Printing, Shipping and Quality Departments.
• Actively participated in the formal complaint resolution program using 8D problem solving methodology ensuring that preventative actions were implemented.
• Successful in implementing a scrap monitoring program which facilitated accurate data collection.
CROWN Metal Packaging Canada LP; (Formerly Crown Cork & Seal Canada Ltd.)
A division of Crown Holdings Inc., a world leader in metal packaging technology.
MAINTENANCE & TRAINING MANAGER – LITHO / COATING & LITTELL DEPARTMENTS;
PLANT #244-****-****
• Co-ordinated the overall maintenance and repair plans for 7 Coating, 3 Litho Print lines and 2 Coil Shearing Lines. Effectively supervised of a team of 40 unionized maintenance and production employees in 2 distinct unions (USW and CEP) within a 24/7 continuous operation.
• Successfully managed a budget of approximately $1M per annum. Consistently achieved department savings of approximately $100K per year through contract negotiation and pricing reductions in parts, service and equipment.
• Maintained two 30 year old coil shearing production lines (capable of processing over 150 miles of metal daily) through following and refining a strict repair and maintenance schedule. Over 2 years, increased efficiency by 5% by reducing lost time due to breakdowns.
• Trained staff and contractors, conducted audits, on Workplace Health & Safety guidelines, OHSA and WHMIS requirements in accordance with regulatory and corporate requirements.
• Developed and implemented a computerized Preventative Maintenance Program based on the 52 Week Rotating Schedule that streamlined processes and maintenance checks; the program was later adopted by other plants with similar equipment and production requirements.
• Initiated quarterly temperature checks/audits on Coating/Litho Ovens. Tune-ups were regularly completed on natural gas burner flames which benefited the plant with lower energy costs and a cleaner working environment. This also resulted in cost savings of over $50K for the first year.
SHIFT SUPERVISOR – LITHO AND COATING DEPARTMENT; PLANT #244-****-****
SHIFT SUPERVISOR – LITHO AND COATING DEPARTMENT; PLANT #233-****-****
• Co-ordinated the activities of over 75 employees in 2 distinct unions on a particular 8 hour shift. Ensured employee safety, maximized quality production, controlled spoilage and defective material.
• Maintained an open-door policy and initiated daily team meetings to encourage positive staff relations and hold employees accountable for safety and work performance.
• Expedited a return to production by quickly facilitating emergency repairs and purchasing materials for broken equipment.
• Reduced costs and waste by collaborating with Coating Suppliers to dispense of outdated/expired materials and rework where necessary. Savings represented over $250k annually.
• Ensured customer satisfaction by conducting online colour proofing of designs, supervising the litho press for each colour pass and collaborating with consumer marketing agents and the customer for final colour approval.
• Developed and implemented numerous individual Coating and Litho Standard Operating Procedures which helped Plant #233 reach ISO 9001 Certification.
• Member of the Plant #244 team that was awarded the Canadian Corporate Award for Most Improved Plant Operation for the year 2000 for cost improvement, quality and overall plant efficiency.
AFTERNOON SHIFT PLANT SUPERINTENDENT; PLANT #233-****-****
• Successfully supported the Plant Manager in all aspects of plant operations and performance on the afternoon shift. This included production, materials, maintenance and manufacturing engineering execution involving approximately 85 production/materials staff, 1-2 maintenance technicians, and 3 team leaders.
• Slashed spoilage costs by initiating and leading a Corrective Action Team composed of plant employees and management to deal with the issue of spoilage and excess waste in the Litho Department. Within the first 3 months, spoilage dollar value was cut by over 100%, from $75k to $34k per month.
• Awarded the 1995 Crown Canada President’s Award for Corrective Action Team success and was later submitted for consideration and evaluation as one of the international finalist entries.
PRODUCTION SUPERVISOR, CAN LINE (AEROSOL) DEPARTMENT; PLANT #233-****-****
• Supervised and provided training to 30 employees within a 7 line aerosol can production facility.
• Effectively managed resources ensuring master schedule adherence in order to meet production requirements.
EDUCATION AND PROFESSIONAL DEVELOPMENT
• Bachelor of Arts, York University, 1988
Professional Development Courses:
• OHSA & WHMIS training, 2007
• First Aid and CPR, St. John’s Ambulance, 2005
• Part IV Fire Code Compliance, Flammable & Combustible Liquids, 2000
In-house Training on:
• Statistical Process Control, Six Sigma, 5S, SMED, Lean Manufacturing, and Good Manufacturing Practices
TECHNICAL SKILLS
Proficient in the use of MS Word, Excel, AS 400, PowerPoint and Kronos
PROFESSIONAL MEMBERSHIPS
Member, National Metal Decorators Association
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