Manager Engineer

Objective

To obtain a position within your organization; leveraging my skills while continual learning allowing me to take on increased responsibilities in the future.

Professional Experience

02/2012 – 05/2012 Thermasys Corporation Montgomery, AL

Production Manager

Lead & manage operations for a specialty heat exchanger manufacturing plant.

Reorganized the production staffing to enable a 33% capacity increase without adding head-count.

Lead Operational Excellence efforts. Highlights:

Successful in achieving “Level-2” 5S compliance within 3 months.

Lead Kaizen event to improve mill up-time by 5.7% through use of LEAN stand-work principles.

04/2007 – 02/2012 BD (Becton-Dickinson) Columbus, NE

Manufacturing Manager

Lead & manage manufacturing operations in a high speed manufacturing pharmaceutical/medical device plant. Includes:

Directing the activities of 4 exempt direct reports while managing a larger organization of an additional 11 exempt professionals and 22 non-exempt lead associates.

Ultimately responsible for a non-union labor force of over 500 employees across multiple shifts.

Responsible for the safety program; our organization currently maintains one of the lowest OSHA recordable rates & highest Safety Index measure in BDX.

Responsible for the training program used to ensure compliance in the plant.

Successfully reorganized the production unit under a single production manager within the plant; selected to be the sole leader of this streamlined organization.

Coaching & developing direct reports to greater levels of responsibility and leadership:

Developed two direct reports to fill Production Leader positions with BD.

Developed another direct report to fill a multi-shift role within my area.

Direct reports are consistently rated in the upper ranges for both performance and future potential within the division.

Consistently exceeding overall cost performance for areas of accountability; $54 million in direct labor & materials; $3 million in overhead & period cost budget.

$5.8 million favorable to budget in 4th fiscal year of performance.

$3.1 million favorable to budget in 3rd fiscal year of performance.

$3.2 million favorable to budget in 2nd fiscal year of performance.

$1.6 million favorable to budget in 1st fiscal year of performance.

Lead Operational Excellence efforts. Highlights:

Successful in reducing overall direct headcount by 7% (50 associates) while increasing output by 20%; represented $2 million in budgeted productivity savings.

Established waste tracking system and lead waste reduction program in SCF area to reduce waste by 10%; represents annual savings of more than $200K.

Restructured production organization to increase associate engagement.

Implemented Production Leadership Program.

Developed Lead/Supervisory Training program in conjunction with HR (F.L.I.T.E School).

Transitioned technical positions to a merit based performance system.

Successfully introduced Lean manufacturing principles to the facility to eliminate waste.

Developed and piloted a production ANDON system to drive daily performance.

Reduced WIP by 25% through KANBAN and “supermarkets” mentality of scheduling.

Increased schedule compliance to highest in division (>95%).

Reduced overtime requirements by more than 50%.

Member of an international team to obtain FDA certification to 21 CFR parts 210 and 211 for the division. Led local efforts in manufacturing areas to ready the operation for certification audit.

12/2000 – 04/2007 PPG Industries Crestline, OH & Tipton, PA

Site Manager & Process Engineer

Managed all aspects of a JIT value-add operation in the automotive industry.

Set-up the entire current operation from the ground up in two years.

Directed the activities of 6 direct reports (Logistics Manager, Quality Manager, Maintenance/Engineering Manager, Staffing Manager, Product Engineer, & Customer Service Representative).

Responsible for a non-union direct labor force of ~140 employees.

Delivery of a quality product as a Tier #1 JIT supplier to the automotive industry.

Led efforts to obtain both Quality & Safety certifications (QS & TS) for plant at start-up.

Overall cost performance of the entire operation; $50 million in direct materials & labor; $4 million in overhead & period cost budget.

Successful in managing the operation from a Lean perspective to eliminate waste.

Maintained the lowest in-direct-to-direct labor ratio of all PPG Satellite operations. This represents savings of ~$400K/year when compared to similar operations.

Re-engineered the lace application for a product line to improve product performance, reduce defects, and increase efficiencies. Total project savings were greater than $600K/year.

Developed a plant floor layout that allows for direct associates to manage their areas without assistance from outside sources.

Both raw and finished materials automatically cycle on a FIFO basis.

Employees “self-schedule” production based on Lean “supermarkets”.

08/1997 – 12/2000 Duracell Lexington, NC

Process Engineer & Production Supervisor

Managed a cell manufacturing area that included 50+ non-union employees across three shifts. Directed the activities of off-shift employees through the off-shift supervisors.

Led the battery assembly department to record scrap and productivity achievements never before realized since the product’s inception.

Efficiencies rose from 85% to over 92% while reducing scrap rates to less than 5%.

Implemented process improvements representing average yearly savings of $500,000 each year.

1st Year: Reduced finished cell scrap due to low voltage by ~60%.

2nd Year: Improved anode welding; doubled electrode life & 75% waste reduction.

3rd Year: Reduced cathode-to-anode alignment scrap by more than 25%.

Education

1992-1996 Georgia Institute of Technology Atlanta, GA

Bachelor of Science Degree, Chemical Engineering

Dean's List

Awarded a United States Air Force four year scholarship

Skills

PPG Sigma Logic Catalyst (Equivalent to Six Sigma Black Belt)

PPG Lean Practitioner (Equivalent to Lean Sensei)

Efficient user of all MS Office applications; able to master new software quickly

Processes familiar with:

Glass Syringe & Component Fabrication & Washing – thermal cutting & forming, needle & tip cap assembly, washing in ISO Class 6 & 7 clean room operations.

Glass Assembly – rubber/plastic trim & datum application, mechanical assembly and bonding operations, and priming application; some injection molding

Glass Fabrication – NC glass cutting, break-out and edging, glass bending and tempering, & industrial silk screening operations

Primary electro-cell manufacturing/assembly – plastic welding, metal-to-metal bonding, component winding, cell filling, metal bending & crimping, spot welding, and metal extrusion.

Logistics Systems – production scheduling, shipping, receiving, purchasing, and raw material acquisition

QS, TS, & cGMP quality systems (including safety systems).

Some injection molding experience

Awards & Achievements

Eagle Scout Award

Leadership Davidson County Graduate

Self-financed entire education without any assistance from other sources

Served a two-year mission at my own expense for my Church. Held many leadership positions related to this mission.

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