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Click here or scroll down to respond to this candidateCandidate's Name
Cell: PHONE NUMBER AVAILABLEStreet Address Gage DriveMooresville, NC Street Address Email: EMAIL AVAILABLESUMMARYProfessional with 30+ years of handson technical and management experience in the plastics manufacturing industry. Possess a global understanding of manufacturing processes and how they relate to long-term success. Skilled leader with proven successes in the following areas:Plant ManagementTeam LeadershipQuality / Waste ReductionStaff ManagementProcess ImprovementEmployee RetentionResearch and DevelopmentProcess EngineeringProcedures and TrainingProject ManagementCAREER ACCOMPLISHMENTSUnited Plastics Corp (Sheet Extrusion/Thermoforming/Injection Molding/Automotive)2017-PresentCapital and Process Improvement Manager/Plant ManagerDesign, develop, update, document and communicates manufacturing processes and technical parameters that meet product specifications and supports company goals on safety, quality, cost and delivery.Develop and implement procedures to analyze manufacturing data i.e. production control charts, reliability, process capability, in order to identify the root cause of production losses and improve operational efficiencies.Evaluate and optimize processes and equipment to generate cost savings through waste reduction, set-up and run time efficiency improvement and quality improvements.Prepare and validate various engineering deliverables such as manufacturing development plans, work instructions, process data sheets, equipment selection, process review and analysis reports, change management documentation, and capital improvement projects in support of operational excellence.Develop new processes, research emerging technologies, and execute characterization and optimization studies of current processes using design of experiments, root cause analysis, troubleshooting and decision-making tools.Utilize systematic problem solving methodology and project management for sustainable improvements.24/7 support of manufacturing lines to include identifying and resolving equipment/material/training/process issues, and coordinating activities of maintenance, quality, production and other resources to execute cost effective solutions.Provide subject matter expertise to other departments and technical mentorship to the manufacturing team.Oversee production scale-up of developmental products and assist in training of operators on all manufacturing phases and in-process control procedures.Write or modify Standard Operating Procedures (SOP) when transferring new or modified technology to production.Recommend safety practices with respect to material handling, processing, environmental impact, waste, etc.Collaborate with suppliers on equipment design, process innovations and raw material alternatives.Other duties as assigned.All Phase Extrusion (Foam Profile Extrusion) 2016-2017ConsultantDirect problem solving -- Increase production rates, reduce profile gage variation, and analysis product failure in the field and recommend long term solutions.Materials management --Recommends quality tests for incoming resins and additives scrap reduction and more economical re-use, propose additives to improve product performance.New product development -- Product testing, analysis of competition, recommend raw materials for application, and equipment retrofits.Installations- Complete line installations, price negotiations, and startups.Roberts PolyPro (Sheet Extrusion/Thermoforming/Injection Molding) 2016-2017Production/Logistics ManagerMaximize the productivity of the extrusion linesResponsible for developing and implementing production/processing methods and controls to meet quality standards in the most cost efficient mannerPerform investigation and resolve work-in-process problemHandle the tasks of recommending and implementing improvements and modifications in sequence of operations, equipment utilization and related mattersMonitor assigned operations to assure compliance with approved methods and quality standardsResponsible for developing and implementing production/processing methods and controls to meet quality standards in the most cost efficient mannerPerform investigation and resolve work-in-process issuesProcurement of all raw materialsProduction line schedulingPoppelmann Plastics USA (Sheet Extrusion/Thermoforming/Injection Molding) 2014-2016Plant Manager /Project ManagerP&L Responsibilities and all aspects of manufacturing, scheduling, distribution and raw material purchasing for this $25 million custom thermoforming/injection molding plant.Plan, organize, direct and run optimum day-to-day operations to exceed our customers expectationsIncrease production, assets capacity and flexibility while minimizing unnecessary costs and maintaining current quality standards. Increased production in 2014 by 22%Responsible for production output, product quality and on-time shippingAllocate resources effectively and fully utilize assets to produce optimal results.Recruited to elevate the plant to a new level of quality awareness and to increase profit margin with introduction of new product.Implement strategies in alignment with strategic initiatives and provide a clear sense of direction and focusMonitor operations and trigger corrective actionsShare a trusting relationship with workgroup and recruit, manage and develop plant staffCollect and analyze data to find places of waste or overtimeCommitment to plant safety proceduresDeveloped systems and processes that track and optimize productivity and standards, metrics and performance targets to ensure effective return on assetsAddress employees issues or grievances and administer collective bargaining agreementsPlanned and installed all new assets from sheet line extrusion, thermoforming, and injection molding machines.Berry Plastics (Customs Films)EH&S/Capital Project Manager 2011-20141. EHS Leadership / Collaboration and Planning80/20 (Strategic Planning / Tactical Hands On)Total Compliance Overview and EHS Strategy for site locationLead a strong EHS team of SMEs to develop best practices in SQRAFacilitate / Integrate PSM & EHS capabilities into plant operationsActively participate in local emergency planning and response teams2. Process Safety ManagementLead PSM Program InitiativesProcess Hazard Analysis (PHAs)Lead Change Management and Regulatory ComplianceHelp to develop best practices on site.3. New Product Process ReviewsNPRs always under reviewRevisions to permits and regulationsReview, modify and approve SQRA SOPPsContinuous improvement of administrative systems and data management for both permitting and process business and operational needs4. Project ManagementLine and equipment installations.Capital Equipment justification and analysisCapital budget management.Training responsibilities of all new equipment installs.Process engineering responsibilities.Cost reduction management.Plant engineering responsibilities.InvistaFirst Line Manager (Polymerization/PET Sheet Lines) 2007-2011Operate area within approved budget & operating guidelines.Responsible for the production of quality product in the safest, most efficient, cost effective manner.Provide team members with work assignments, training, feedback, coaching, support, and development opportunities; ensure adherence to company policies.Manage the daily workflow and implement process changes, ensuring productivity standards & goals are met; positive communications & proactive solving.All Phase Extrusion 2006-2007ConsultantDirect problem solving -- Increase production rates, reduce profile gage variation, and analysis product failure in the field and recommend long term solutions.Materials management --Recommends quality tests for incoming resins and additives scrap reduction and more economical re-use, propose additives to improve product performance.New product development -- Product testing, analysis of competition, recommend raw materials for application, and equipment retrofits.Installations- Complete line installations, price negotiations, and startups.Atlantis Plastics, Inc. 2005-2006Plant Manager (Custom Films)P&L Responsibilities and all aspects of manufacturing, scheduling, customer service, distribution and raw material purchasing for this $37 million custom film plant.Recruited to elevate the plant to a new level of quality awareness and to increase profit margin with introduction of new products.Increased production output by 20% with minimum capital expense.Successful installation of the companies first five layer with minimum startup scrap.Recorded record profit levels in the fourth Qtr of 05 due to implementation of good manufacturing practices and resource recruiting.ISO Poly Films, Inc 2004-2005Plant Manager/Capital Project Director (Custom Films)Responsibilities for all aspects of manufacturing, scheduling, distribution and raw material purchasing for this $36 million custom film plant.25% increase in productivity with no major capital expenditures.Record EBITDA FY04 achieved through increased margins via raw material cost savings of $.05/lb as well as scrap reduction programs, higher throughput rates and significantly reducing customer complaints.Installations of all 3/5/7 layer lines and successful startup.LINPAC Plastics, Wilson, NC 2002-2004Extrusion Manager (Foam Extrusion)Reduced the sale of off-specification scrap by implementing a recovery program to reduce the amount of scrap generated; enjoyed a savings of $12,000 every six weeks.Introduced a chemically activated nucleating agent that reduced gas input. Resulted in a $235,000 annual savings. Also increased rate and decreased off-spec material.Introduced a data base that tracks all quality complaints giving a better feel of where defects originate.Worked closely with color concentrate vendors to develop concentrate that gave excellent results at a greater cost savings. Resulted in a 25% reduction in overall cost of color concentrate.Detroit Forming, Inc. Spartanburg, SC 1983-2002Plant Manager, Extrusion Plant (OPS Sheet Extrusion)Started as front line supervisor and advanced position to plant manager. Other positions include R&D Manager, Training Superintendent, Production Superintendent, and Maintenance Manager.Spearheaded the design and construction of one of the industrys first constant feed blender systems. Enabled the company to enjoy a more uniform blend of material and resulted in better pumping capabilities of our extruders.Substantially reduced the dead time and loss of productivity in the slitting department by installing a material handling and packaging system. Beat the deadline on this project by 2 months by taking advantage of the engineering services provided by the machine vendors.Developed extruder heat profiles that generated a 10% increase in output and reduced power consumption.Developed a silicone coating system reducing outside sheet customer complaints by 70%.Decreased lost time injury rate and increased the level of product quality by developing and implementing a comprehensive training program.Leadership provided as a Plant Manager resulted in a drop in employee turn over rate from 20% to less than 5% within a two year period.EDUCATION/TRAININGWestern Carolina University Cullowhee, NCContinued professional development training focused on various courses to insure increased and current knowledge of manufacturing processes including electrical, electronics, pneumatics, mechanics, and hydraulics. Other courses taken to enhance management abilities include a range of courses from beginning supervision to advanced management and planning. |
