| | | 20,000+ Fresh Resumes Monthly | |
|
|
| |
Click here or scroll down to respond to this candidateCandidate's Name
Paducah, KY Street Address PHONE NUMBER AVAILABLE EMAIL AVAILABLELINKEDIN LINK AVAILABLEQUALITY/OPERATIONS DIRECTORResults-oriented quality and operations leader with deep expertise in the manufacturing industry. Proficiency in process optimization, Lean and Six Sigma manufacturing, culture building, quality management systems, business strategies, and cross-functional collaboration for business success. Extensive and versatile experience in leadership roles spanning both Operations and Quality management, showcasing a comprehensive understanding of how these critical functions connect to drive organizational success. Passionate about developing talent, leading teams, and leveraging skills that enable the organization to achieve success.Safety Leader Zero Defects Culture Building Lean Manufacturing Black BeltTeam Building Talent Development Collective Bargaining FMEA Change ManagementERP Customer Requirements Quality Management Multi-Site Benchmarking ISO 9001 KPI FocusProfit Driven Consumer Focused Hygiene Standards Leader Standard Work PHAProfessional ExperienceH.B. Fuller Adhesives, Paducah, KY March 2021 PresentA $3.5 B Specialty Adhesives Manufacturer; the worlds largest pure-play adhesives company with more than 6,000 employees worldwide.Quality Improvement Director/Manager, January 2023 - PresentDirected the Quality Management of $32 million in business for Hot-Melt quality and manufacturing with multi-site benchmarking and integration of best practices throughout the GBU. Responsible for Hot Melt manufacturing businesses including raw material supply, manufacturing, packaging, shipping, and customer complaints and audits each requiring unique quality management and business strategies and solutions. Managed Engineering, Continuous Improvement, Recipe Management, Quality Assurance, Quality Control, and all Rework teams. Customer facing role with constant and direct interaction with customers to solve problems and find novel solutions for processing and performance initiatives. Part of the leadership team and acted as the voice of the customer within the organization. Directly managed a team of 12 Engineering and Quality Managers. Developed Hygiene Requirements and KPIs for Engineering, Quality Operations, Continuous Improvement that were benchmarked across the business. Managed all QMS elements and the subject matter expert for ISO 9001:2015, EDANA Standards, Food Safety, and Quality Assurance Key Elements (QAKE) Hygiene Standards. Restructured direct and indirect reporting teams to optimize overhead costs and address leadership gaps. Provided structures to make customer and financial based decisions, reducing cost of poor quality by 80% Responsible for new product introduction to meet novel customer needs from development to scale-up. Recipe and formulation design with R&D, raw material sub-pool development, and development of inspection plans. Integrated new products from two separate business acquisitions. Conducted Management Reviews to identify shortcomings in the QMS and helped identify the need and then implement a Global electronic Quality Management System. Mentored a young team to embrace constantly evolving business goals to exceed customer requirements driving a culture change from blaming to solving. Increased Shipped in Full On-time (SIFOT) by 30% by overhauling manufacturing processes to reduce off-spec and disposal costs Developed HACCP and Contingency Plans for Hygiene and Food Safety Certified manufacturing facilities. Stabilized Quality across the Hygiene Business by adapting best practices to multiple sites and attaining high scores on customer audits across the business Reduced downtime and manufacturing costs by optimizing product recipes through an interdisciplinary team and driving batch adjustments from ~15% to less than 1.5% Implemented a broad product wheel restructuring to stabilize quality and reduce raw material and processing costs to help grow Contribution Margins on Automotive and Hygiene Products.Sr. Facility Technical Manager, January 2022 January 2023Directed aspects of site quality and operations at the facility across 8 batch reactors and consisting of 120 employees. Led a team of engineers and managers, including Quality and Engineering Managers, overseeing 24x7 manufacturing operations. Responsible for rework, scrap and waste, product wheel, QA/QC, Capital Projects, and customer/internal audits. Also helped develop and oversee plant costs and business initiatives including Supplies, R&M, Factory/Indirect Labor, Manufacturing Leverage, SIFOT, Schedule Attainment, and production targets. Relentless focus on continuous improvement efforts to drive reliability in safety, quality, and productivity leading to year over year improvements in Customer Audit Scores: 95%, 90%, 100% on three major customer audits. Developed and deployed PSM Standards to a non-PSM site including PHA, LOPA, FMEA and other Process Safety methodologies and standards. Optimized zero-defect quality standards, preventative maintenance standards, and demand planning processes, utilizing Operational Discipline (OD) and Leader Standard Work (LSW) as our paths to success. Reduced year over year plant supplies costs by $1,000,000 Reduced Scrap & Waste costs by $300,000 year over year by optimizing product wheel and production requirements to eliminate single batch runs and schedule longer campaigns to reduce change over scrap and cost Lowered product adjustments by nearly 10% resulting in a Raw Material cost reduction of over half a million dollars thus reducing the negative impact on product contribution margins.Plant Quality Manager, March 2021 January 2022Led all aspects of the Quality Management System for a 24x7 production facility with 120 employees, overseeing the site auditing, product wheel, recipe management, continuous improvement, S&W, Cost of Poor Quality (COPQ), 8D/RCA, and Customer Complaints. Managed annual Management Review and KPI development and deployment driving year-over-year quality and manufacturing improvements. Implemented a broad culture change initiative of decentralized decision-making for improved efficiency and accountability throughout the facility. Established robust operational procedures with detailed deviation reporting requirements to drive efficiency, mitigate risks, and enhance quality. Reduced customer Quality Incidents (QIs) from over 120 in 2020 to 23 in 2022 via broad culture change initiatives Implemented hyper care initiatives: Validation, strict change management, standard work, deviation reporting, and employee engagement and recognition to foster a culture of individual ownership of processes and products. Procter & Gamble Customer Audit score improved from 71% to 92% to achieve the highest audit score in company history with P&G. Highest Audit score in Essity/SCA history across all their suppliers under my leadership Solved customer complaint issue to win a $25 million dollar customer accountWacker Chemical, Calvert City, KY July 2017 March 2021Production Reactor Engineer IIResponsible for a team of 6 Union Operators and two High Pressure Polymerization Reactors including production scheduling, batch classification, process optimization, troubleshooting, minimizing downtime, identifying delays in batch processing and transfer, and resolving quality issues.The primary role was to direct operators on batch recipe changes, polymer characteristic adjustments, and preventing and classifying B-Grade material. Directly responsible for checking, troubleshooting, and fixing pump capacity issues, batch cooldown timing, temperature tracking, and flow issues. Identified systemic changes in reactor/batch performance, and maintained daily operation of DI water systems, chemical stripper units, chemical cleaning process, and recycle/condensate lines.Conducted Process Hazard Analysis as a process engineer at a PSM regulated facility; including PSSR and MOC documented work covering $6MM in inventory. Accountable for managing the order entry process, customer complaint investigation, shipping & receiving, production scheduling and all aspects of Quality Management for my equipment and products. Established and maintained SOPs for all equipment and processes and was responsible for elements of cost, delivery performance, inventory turns, and disposals. Utilized SAP to manage all aspects of scheduling, quality, and production. Drove sustainability initiatives to reduce consumption of Ethylene and flare/thermal oxidizer emissions Led Process Hazard Analysis events for high pressure reactors at a PSM facility. Implemented process improvements to reduce downtime for Reactor Cleaning by optimizing Chemical Clean solution changeover processProfessional Achievements:EHS: Helped drive EHS initiatives to eliminate all recordable/lost time injuries over a 2+ year period. Rigorous focus on employee culture, feedback loops, auditing, guarding, and procedure adherence. Achieved Responsible Care Certification from the American Chemistry Council. Helped roll out permit to work program and interlock bypass program Reduction of Trash Hauling Costs and Solid Waste Footprint from 40 metric tons/month to 10 MT/month Ideated the initiative to optimize batch transfer protocols to reduce ethylene gas usage by 120,000 lbs./month Developed and deployed PSM standards to non-PSM facilities to strengthen the process safety culture. This includes PHA, LOPA, FMEA and rigorous change management, LOTO, and safe work permitting standards. Rolled out the implementation of the EPA PVC MACT initiativeQuality: Fostered a zero-defect culture with a focus on both internal and external product failures. Reduced customer complaints by over 70% over a 4-year period utilizing 8D problem-solving. Improved P&G 19 Key Elements Quality score from 71% to 92% securing preferred supplier status. Achieved Food Safe and SMETA certifications in aging plants, securing over $15MM in new business with Nestle, Kraft Heinz, and Anheuser Busch. Built a culture of Operational Discipline to eliminate production variability, reducing blown batches by over 40% Reduction in batch-to-batch variability thus nearly eliminating raw material/processing adjustments. Reduced adjustments from >30% to 1.5% over a 3-year period. Overhauled multi-site validation system to standardize Validation and MOC requirements and helped to exceed customer requirements. Hygiene site benchmarking to standardize FMEA process across all Hygiene sites including contingency planning. Rolled out Global electronic QMS system for tracking and managing customer complaints, MOCs, internal complaints, and site action tracking system. Implemented a standardized ISO auditing system across 3 Hot-Melt manufacturing sites Developed fully automated learning management system with automatic training notification for managers.Cost/Productivity: Relentless drive toward continuous improvement through cross-functional teams and executing targeted initiatives and kaizen events. Reduced scrap & waste from $2.1MM to $0.6MM/year utilizing lean and six sigma methodologies. Optimized tight capital budget to grow hygiene capacity by over 3,000 metric tons with minimal investment Improved capacity by over 15% through product wheel and lean manufacturing principles to delay capex investment for new business. Improved OEE through the implementation of individual ownership, clean to inspect, and GEMBA walks Managed a 5% YOY productivity improvement pipeline utilizing lean manufacturing and capex. Black Belt project - reduced supplies spend from $2.4MM to $1.2MM per year Optimized operational footprint to reduce headcount and overhead costs. Successfully reduced Headcount to below budget without losing any capacity Oversight of budget planning & adherence Secured $25MM account via solving customer issues and optimizing their product delivery systemPeople: Built high-performing teams by recruiting, developing, coaching, and mentoring staff to excel in their roles. Ability to lead cross-functional teams across a wide range of departments to align around common goals and deliver results. Stepped in to support struggling sites/departments as needed. Constantly helping other sites and business units to optimize processes and systems to drive culture change and/or quality initiatives. Directed initiatives to foster diversity and inclusivity to drive high performance teams. Sponsored and helped develop the Talent-up program to identify, train, develop, and promote high potential employees. Successful pilot program now in its third year. Received one of the highest scores for employee engagement in H.B. Fuller, 80% Received multiple recognition awards for exceeding all targets related to productivity, cost, safety, delivery, and quality. Ability to drive results through cross-functional teams with varied reporting structures Drove a broad culture change initiative to drive Customer Focused Quality initiatives and achieve total employee engagement. Implemented safe work practices such as permit to work, LOTO, and rigorous change management with interlock bypass procedures.Strategic Planning: Developed Hot Melt annual SWOT and 1- and 5-year plans with SMART goals related to the five pillars of operational success: Safety, Quality, Delivery, Cost, and People. Successfully integrated multiple acquisitions: Products, People, and Customers Completed departmental restructuring efforts to effectively meet new challenges. Recruited, developed, and mentored staff to excel in their roles with a run/improve plant model. Helped build private label operational capabilities supporting millions of dollars in new sales. Focused on speed to execution with a time-phased roll-out for immediate payback with long-term sustainability. Complete restructuring of Product Wheel and Scheduling to increase on-hand inventory of fast-moving products and reduce inventory of slow moving and aged inventory. Eliminated single batch runs and optimized production lines to run long campaigns to reduce Change Over via Lean Principles.Supply Chain Integrated new products from acquisitions into the Company SAP ERP system including recipe building, formula design, raw material sub-pools, quality inspection plan development, and regulatory requirements. Worked with sales and customer service to build and roll out Material Master requirements and then deploy to all manufacturing sites. Established KPIs and Executive Summary report providing business strategy recommendations and cost management direction. Designed and implemented inventory requirements to optimize product wheel and campaign length requirements Developed contingency plan models across Hot Melt manufacturing sites Maintained 90% delivery performance throughout the Covid Pandemic. Optimized product wheels to improve schedule attainment and order delivery, increasing delivery performance to over 95%. Reduced scrap & waste by over $2MM. Rolled out SAP modules to manage lot scanning to reduce delivery complaints by 90%. Optimized warehousing footprint to close external warehouses saving $1.8MM annually. Successfully integrated multiple business acquisitions into current capacity limits Leader in crisis management including RM shortages, Fires, and Spills.Additional Relevant ExperienceSuperior Graphite Company June 2016 July 2017Sr. R&D Pilot Plant ManagerResponsible for a team of 4 employees and $10MM in Pilot Plant inventory. Accountable for managing the order entry process, customer supply programs, quality management, costs, and imports/exports of customers trial materials.Coordinated and ran day to day operations of the R&D Pilot Reactor group and supported the main production facility via trials and scale-up initiatives. Designed, machined, built, and trialed graphitized fluidized bed reactors and managed all aspects of the pilot plant facility. Project manager and lead process engineer on off-gas optimization and redesign project; flue gas desulfurization specialist to reduce particulate emissions and SOX and NOX emissions and Title V compliance through the EPA. Optimized graphite part manufacturing to reduce costs and downtime. Debottlenecking initiatives to increase throughput and decrease direct cash costs of the Pilot Plant Facility. Designed and installed fluidized bed reactors, bulk solids handling equipment, and liquid/gas equipment.Wacker Chemical Calvert City, KY May 2014-July 2015EHSResponsible for the day-to-day operation of the EH&S department including hazardous waste classification, storage and shipping, incident reporting and investigation, and safety/environmental auditing and record keeping. Compiled and submitted quarterly, semi-annual, and annual compliance reports for EPA regulations. Maintained records of raw materials and new chemicals. Directly worked on the institution of the PVC MACT regulation from initial testing to final rule institution and directed all sampling and testing. Coordinated polymer classification analysis to resolve HAP contamination issues reported by outside laboratory.Professional CertificationsLean Six Sigma Black Belt CertificationAIChE Training, Inherently Safet Design, Combustible Dust, Thermal/Runaway Reactions, Laboratory Safety7 Habits of Highly Effective Leaders, Franklin CoveyLead Auditor ISO 9001:2015: ASQ/DEKRAQAKE Auditor: Procter & GambleEducationMaster of Business Administration (MBA), Murray State University (Enrolled)Bachelor of Science Degree Chemical Engineering (BS), University of Kentucky |
