Manufacturing Professional

MATTHEW A. LIEFERMAN

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

Camanche, IA. 52730

ziz0ea@r.postjobfree.com

Home: 563-***-****

Cell: 563-***-****

PROFESSIONAL SUMMARY

Talented professional with extensive supervisory, quality and management experience in manufacturing with a successful record for internal advancement. Known for out of the box thinking, identifying and implementing process improvements, exceeding stretch business goals and involving all levels of the organization to be part of the team. Highly resourceful and adaptive; take “crash projects” in stride and continually volunteer for additional responsibility.

PROFESSIONAL EXPERIENCE

Alcoa, Inc. Davenport Works Ingot Plant, Riverdale, IA 1992 - 2009

Senior Manufacturing Engineer 1999 - 2009

Responsible for leading department Process Improvement, Total Productive Maintenance and cost saving initiatives through training and team development. Utilizing tools such as Kaizen, Problem Solving and A3 Thinking. With success in implementing new capital projects on time and under budget.

• Achieved cost savings benefit of $4.8 million dollars by increasing purchased recyclable material consumption to 56 million, pounds, exceeding the past 7 years combined. Accomplished with no capitol budget, additional resources, or equipment by applying Alcoa Business System (ABS) Kaizen and Team Development Skills.

• Generated cost savings of 17.8¢/pound, increasing consumption from 0 to 2MM pounds/month by working with Corporate and plant wide EHS for approval to increase Beryllium (Be) restrictions.

• Led Total Productive Maintenance (TPM) kickoff events, achieving TPM Level II in 18 months and Level III in 20 months, recognized as first to achieve Level III TPM at facility.

• Increased Operational Equipment Efficiency (OEE) by 25% while leading process improvement and Lean manufacturing activities to increase departmental productivity.

• Implemented Daily Management Boards at Production Centers owned by the operators that gave an in the moment picture of the daily goal compared to actual production. If production was behind goal the reason would be captured and then would trigger problem solving.

• Saved $687,899/year by reducing operating supply expenses with implementation of process improvements and periodic audits of cost detail records.

• Operated and Maintained tool crib and supplies for maintenance and operating reducing on hand inventory and space required. Resulting in a cost savings of $537,000 initial and reduced monthly supply costs by $150,000

• Worked with process experts and design engineers to transfer knowledge and process from a closing sister plant which took low quality primary material and greatly improved the purity of final product generating savings of 55%.

• Responsible for the training of over 140 employees in numerous programs such as Oracle, ABS, APS, Tough Stuff and TPM

• Developed and presented plant wide communications, including the introduction of “Scrap Man”, to increase awareness of how increased recyclable material utilization impacts Alcoa’s financial plan.

• Served on the Alcoa’s Global Commodities Council for Commercial Metals, which drove the coordination, testing and qualifying of secondary suppliers and leveraged global purchase volumes for various alloying materials for 8 plants. Successes received Corporate wide recognition.

• Redefined and documented 250 operator roles and responsibilities turning SOP’s into 2 to 3 page user friendly visual documents. Implemented and delivered initial training on new processes, conducting weekly status reports and performing new employee coaching and audit process.

• Member of the One Sigma pilot team and led the development of department process flow diagrams and FMEA’s and the Rapid Change Process recognized by BSI as best practice.

• Maintained the Ingot Plant Quality system in conformance with ISO 14001, ISO 9001-2000, contributing to the certification of the plant.

Senior Molten Metal Technician 1995 - 1999

Coordinated equipment maintenance and engineering projects with outside contracting firms. Developed quality procedures and training expectations for the staff and outside contractors. Established supplier specifications and purchase agreements for the ADC storeroom.

• Designed, built and implemented side dams that increased continuous caster run time from 10 to 45 minutes.

Hourly Employee 1992 - 1994

Flat Mill Servicer, Cold Mill Servicer, IPS Inspector, IP Complex Operator.

United States Navy 1981 - 1992

Aviation Electrician 2nd Class, Microelectronics Technician/Certifier for East Coast Region

Responsible for the production and repair of circuit board and cable repair certification of work centers for three Naval Air Stations and managed the work centers on the USS Saratoga.

• Served in Desert Storm as supervisor overseeing a group of 37 Micro-Miniature Technicians.

• Troubleshot and repaired aviation, armament and ship board electronic equipment.

• First enlisted micro miniature technician Recertifier certified by Airlant North Atlantic Fleet

• Certified Mini Mod Repair Collateral Duty Inspector

• Received the Navy Achievement Medal for performance.

EDUCATION

Attending University of Phoenix towards Bachelor’s degree in Business

CONTINUING EDUCATION

• ABS (Alcoa Business System)

• COE (Center of Excellence) Levels 1-3

• Coached and lead 11 Kaizens

• Problem Solving

• Autonomous Work Groups

• TPM (Total Productive Maintenance)

• APS. (Alcoa Production System)

• ISO 14001 Internal Auditor

• Change Management

• Alcoa University

• Supervisor Assessment (Passed)

• Supervisor Role in APS

• Dale Carnegie

• EBS

• Aviation Electrician

• Microminiature Class.B

• Mini Mod Repair Course

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