Process Improvement Manager

DAVID T. CARNALL

* ******** ***** **** ● Sterling, Connecticut 06377 ● Cell: 317-***-**** ● Email: *********@*****.***

OPERATIONS, ENGINEERING, & FACILITIES MANAGEMENT

High performance, results-driven management professional with over 20 years in food packaging, manufacturing, engineering, and maintenance, demonstrating visionary leadership, knowledge, skill, and wisdom in decision making and problem solving. I am a practical catalyst for change, combining tactical execution of strategic initiatives with strong leadership of cross-functional staff development.

SUMMARY OF QUALIFICATIONS

• Supervision/management of personnel Developing union and non-union employees and direct reports through team building, training/education, cross training techniques, improving employee relations, and enhancing work systems.

• Facilities/operational management Driving efforts to be a low-cost producer while maintaining high levels of productivity and quality. Budget planning, cost reduction initiatives, reducing waste, and increase process efficiencies.

• Engineering/project management Capital project management and implementation, facility and equipment layout and design, process improvement and re-engineering, and computer integration/automated manufacturing.

• Equipment sales, purchasing, and negotiation of performance guarantees and contracts for capital projects, specifically packaging, corrugated, and converting equipment.

• Well versed with systems/applications tailored for the corrugated/converting industry, manufacturing and maintenance programs (proprietary and standard business), all Microsoft Office products, Computer Aided Design (AutoCAD), project management software, among other systems/applications.

PROFESSIONAL SUCCESSES

• Designed, justified, and implemented over $25 million in capital projects.

• Realized single year profit gains in excess of $100,000 by identifying reporting errors in manufacturing return data.

• Instrumentally involved in cost reduction project leading to the re-development of microwave popcorn packaging.

• Facilitated the closing proceedings of an International Paper facility (closing due to acquisition of competitor and overlapping manufacturing locations) 3 weeks ahead of schedule and with the smoothest plant-closing transition to date, which included seamlessly transferring customers, tooling, and equipment to appropriate facilities. Coordinated closing with local and state officials and arranged employees’ unemployment benefits and job training/development programs.

• Reduced corrugated waste and yielded a $250,000 per year savings.

• Uncovered a systematic calculation error overstating production costs and added $150,000 to the facility’s bottom-line in 2009.

PROFESSIONAL EXPERIENCE

Process Improvement Manager International Paper - Putnam, CT/Hartford City, IN July 2004 – Present

Responsible for continuous improvement efforts related to corrugated manufacturing. Initiate and create capital projects with cost justification through equipment research, project management, engineering, and design. Highly involved with employee development, manufacturing initiatives, and personnel management.

• Drive, lead, and monitor all continuous improvement activities (Manufacturing Reliability System), involving quality, preventative maintenance, benchmarking, and center-lining. Liaising with manufacturing, engineering, and management personnel.

• Key role in ensuring manufacturing facility and employees succeed in meeting corporate goals, strategic and implementation plans, cost savings, continuous manufacturing excellence, safety, quality, and customer satisfaction and retention.

• Conduct Lean Manufacturing and Kaizen events; lead weekly manufacturing reliability meetings to review progress; outline projects; and review production efficiencies, quality issues, and maintenance performance.

• Track and report all key performance indicators.

• Develop training for new/existing employees for quality and center-lining SPI’s.

• Assist supervisors in developing their personnel relations and accountability programs.

• Responsible for operational management in absence of plant manager.

• Maintain OSHA log and Worker’s Compensation records.

• Monitor environmental compliance in accordance with local, state, and federal regulations.

• Manage safety programs and lead facility’s safety committee.

David T. Carnall – Page 2

Field Process Specialist/Sales International Paper – Fort Wayne & Hartford City, Indiana

• Facilitate packaging solutions for customers and provide technical support to the sales team.

• Manage house and national accounts and grow existing business 3-5% the first two years and 8% the third year.

• Complete quarterly/annual sales volume projections and monthly forecasting.

• Packaging Design/Engineering Assist structural designers to create innovative design(s) to fulfill customers’ needs.

Packaging Manager/Plant Engineer Red Gold, Inc., Orestes, IN April 1998 – June 2004

Responsible for the operations of the packaging department (80 employees) year around and manage the plant’s nightly operations (200+ employees) August through October. Additional responsibilities included budgeting/cost development, capital projects, process management, project management, and engineering design.

• Manage all aspects of labeling and packaging Red Gold’s and other customers’ products, with focus on quality, cost management, and achieving production goals. Run all plant operations, migrant camp, personnel, and plant security through night shift hours during the tomato processing season (August through October).

• Develop/maintain annual budget objectives, goals, strategies, initiatives, and support double digit sales and personnel growth by providing clear expectations in a team environment with a no-nonsense approach to automation.

• Administer all labor relations with packaging employees and ensure all employment legalities are compliant. Provide career paths, employee development, and counseling for supervision and operational staff.

• Project management and engineering Initiate and oversee the design, installation, and implementation of millions of dollars in capital projects increasing efficiency, productivity, and labor utilization realizing 100% output growth in five years.

Manufacturing Manager/Sales Engineer Portion Control Technology, Inc., Decatur, AL August 1995 – April 1998

Provide leadership for a producer of custom packaging machinery & conveying systems. Manage all aspects of manufacturing operations, perform technical sales, manage service department, oversee installation of projects and equipment, develop conceptual production layouts, and preliminary equipment designs.

Project Manager/Sales Engineer Ropak Manufacturing Company, Decatur, AL May 1994 – August 1995

Responsible for technical sales, project management, systems design, equipment installation, and customer service for a manufacturer of vertical & horizontal form/fill/seal equipment for liquid/dry products. Create concept layouts and integrate Ropak machinery with other original equipment manufacturers’ (O.E.M.) equipment and conveyors, providing "turn-key systems."

Lead Technical Coordinator Weaver Popcorn Company, Van Buren, IN April 1990 – May 1994

Responsible for the set-up, operation, and maintenance of processing and packaging equipment, achieving optimum productivity and quality levels. Establish a preventative maintenance program and provide specialized equipment and maintenance training. Lead cost reduction teams for packaging materials, production processes, and cost justifications for capital projects.

EDUCATION / CERTIFICATIONS / PROFESSIONAL AFFILIATIONS (past/present)

Bachelor of Science in Business Management

Indiana Wesleyan University, Marion, Indiana

Cum Laude

Associate of Applied Science Degree in Automated Manufacturing Technology

Indiana Vocational Technical College, Fort Wayne, Indiana

Dean’s List

• Six Sigma, Lean Manufacturing, Time Management, and Leadership Training

• National Food Processing Association (NFPA)

• Certified Packaging Professional (CPM)

• Packaging Machinery Manufactures Institute (PMMI) Member

• Member of the IVY Tech State College Technical Advisory Board

• Veteran – United States Marine Corps

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