DAVID S. VOKINS

**** **** ****** ***

Corona, CA 92880

949-***-**** (Cell)

yh8uae@r.postjobfree.com (e-mail)

SUMMARY

Exceptional leader in search of a senior level operations position. Cross functional experience with over 20 years of proven operational improvement and cost reduction. Demonstrated expertise in lean manufacturing techniques, TPS, SPC, and TQM An innovative and effective leader with excellent communication and interpersonal skills and a record of success in managing multi-site operations, warehouse logistics and distribution, plant management, and international manufacturing operations.

EXPERIENCE

BAE Systems Inc. Ontario, CA 2006-2009

(Military, Aerospace, Automotive, and PPE Products)

Plant Manager (Director of Operations)

• Managed the Operations of four business units consisting of five plants, two distribution facilities with over 50,000 SKUs, with over $100MM in sales in a $350MM division of a $31B company. Also responsible for overseas production in China, Vietnam, and Mexico.

• Improved production efficiencies 24% in the past 6 months through headcount reductions and overtime reduction of over 20%.

• Implemented cost reduction program (Kaizen events) tracking at a $700K cost savings by year end.

• Reduced WIP inventory by 55% in 6 months through the implementation of cells and a Kanban system for pulling raw materials.

• Established new product introduction criteria and procedures that reduced the manufacturing ramp up time, minimized scrap and re-work, and improved quality.

• Coordinated the merger of three of the business units saving $3MM annually including the consolidation of 7 facilities into 3.

• Responsible for implementing Lean technologies and Toyota Production Systems into the manufacturing plants improving quality and efficiencies, lowering inventories, and costs.

• Well versed in Kepner-Tregoe project management and BAE Life Cycle Management for new product introduction.

• Reduced the plants’ safety incident rate by 50% through employee meetings, safety contact briefings, and emphasis placed safety.

• Managed materials procurement department for the four business units. Worked with suppliers to speed delivery and inventory of the raw goods setting up a Kanban to pull as needed reducing internal inventory by over $1MM and improved turns from 5.5 to 7.

• Responsible for the procurement and quality of off shore produced product in Asia resulting in $14MM in annual sales.

• Started a contract (Maquiladora) manufacturing operation in Mexicali to produce low end product line previously made in China.

• Implemented a new ERP system (Visual Enterprise) replacing DataFlow.

Scholle Corp. Foothill Ranch , CA 2001-2005

(Flexible Packaging for food, chemicals, and pharmaceuticals)

Division Sr. Engineering Manager

• Managed the Auto-fill equipment Research & Development, Engineering, and Documentation functions. Implemented processes and procedures for drawing control, the Kepner-Tregoe project management system minimizing design time, and an engineering review structure for design for manufacturability.

• Managed the development of the next generation of automatic fillers for Scholle in fresh, ESL, and aseptic versions including in-line and rotary. This included the new patented version of an automatic capping/steam chamber and new fill valve technology.

• Grew department from 10 engineers and draftsmen to 24 engineers, draftsmen, engineering technicians, tech writers, and documentation specialists while reducing overall production budget by $500,000.

• Responsible for sourcing of all raw materials and outside contract machining and design work.

Plant Manager

• Managed 120 employee manufacturing plant and warehouse generating $60MM in annual sales.

• Increased production from 760,000 products per week to 925,000 products while reducing the budget $1.5MM

• Implemented a Kaizen "Blitz" campaign improving productivity 47% in less than two months.

• Reduced customer complaints over 90% through direct customer contacts and responsiveness to customer needs.

• Implemented the BaaN V - ERP system to replace an obsolete ManMan ERP system

• Implemented ISO 9000/2000, first plant in the corporation to be certified to the 2000 standard.

• Implemented a SPC system to make real time machine adjustments to improve productivity and reduce scrap. Machine uptime improved over 20%.

• Maintained “Superior” AIB rating and FDA Certification following GMP practices.

Zebco Div. of Brunswick Corp. Tulsa, OK 2000-2001

(Consumer Products and Sporting Goods)

Director of Manufacturing

• Managed the operations, distribution, and manufacturing engineering functions for three facilities and 600+ employees supporting a three-shift, five-day operation producing 33,000 fully assembled and packaged products per day generating over $600MM in annual sales.

• Implemented lean manufacturing techniques (Kaizen projects), resulting in $120,000 annual savings in die casting and $100,000 annual savings in injection molding.

• Implemented a $3.2MM automated assembly line, reducing labor from 75 persons to 12 persons.

• Directed the sell-off of all plant assets when all production was moved overseas. Sourced/selected the auction service, negotiated the contract, and oversaw the auction, generating $200,000 more than anticipated. Transferred all manufacturing to India and Korea.

Today’s Plastics Dallas, TX 1992-2000

(Toys and Consumer Products)

Director of Operations & Engineering

• Managed the Product Design and Development and Operations of two facilities and a 550K sq. ft. distribution center with 350+ employees supporting a 24/7 operation generating over $50MM in annual sales.

• Implemented 46 new products (including two toys of the year) encompassing 80% of the sales volume; 41 new products were on time, and all products were under budget.

• Managed all activities related to product safety/reliability in a plant that manufactured products for the highly visible toy industry. Manufactured over 60 SKUs in any given year that met applicable safety and regulatory standards (ASTM, EN-71, FDA, AS1647) for the U.S., European, and Australian markets with only one (industry-wide) product recall.

• Determined cost effectiveness of domestic versus overseas (China & Mexico) production. Developed costing analyses, sourced products, hired agents, and oversaw manufacturing start-up. Approximately 30% of the product line was manufactured abroad in Mexico and China.

Engineering Manager

• Implemented a new ERP system (CAS – Computer Associates). Successfully completed project in eight months, one month ahead of schedule.

• Successfully implemented ISO 19000 program and Quality training program.

• Directed the implementation of a plant-wide safety program. Initiated regular safety meetings/ inspections and elevated employees’ awareness of safety issues. Maintained compliance with OSHA regulations and achieved a record of over 1 million man hours without a lost-time accident.

• Implemented six blow molding machines, one 3-arm rotational machine, and rebuilt ten injection molding machines including state of the art controls providing more flexibility in production line layouts and increasing throughput by 75%.

• Responsible for the development, design, fabrication, and implementation of over 100 PLC-controlled automated machines for post molding processes, reducing labor by 30%-40% and eliminating $300,000 CTD costs per year.

• Implemented liquid color mixing system for blow, injection, and rotational molding, reducing colorant expenditures by 5% and significantly improving quality (first in industry for rotational molding).

Rubbermaid – Manufacturing Engineer 1989-1992

Boeing – Sr. Engineer 1984-1989

EDUCATION

University of Kansas, Lawrence, KS – B.S., Mechanical Engineering 1984

Wichita State University, Wichita, KS – Coursework towards MBA 1989

Six Sigma Greenbelt through Honeywell 2003

Contact this candidate