Director/VP/Plant Manager of Operations/Manufacturing in chemical, pharmaceutical, aerospace materials or other manufacturing industry.
SUMMARY
Experienced operations/manufacturing leader specializing in turnarounds and start-ups in businesses facing challenging marketplaces. Proven track record in continuous improvement with a focus on increasing productivity/quality/safety while dramatically lowering operating costs.
EXPERTISE HIGHLIGHTS
· 29 years in manufacturing operations, 15 years in general/executive management of multi-site, multi-plant, batch and continuous operations.
· Led turnaround of two acquired manufacturing sites. In both sites, realized 40-50% productivity gains while reducing costs 25-30%.
· Elevated customer satisfaction 80% through aggressive quality/delivery improvement and intensive communication enhancement.
· Reduced injury rates by 75-90% in 3 separate plants using behavior-based safety and culture modification programs.
· Achieved 60% increase in productivity to attain the best-in-class automotive coatings plant in the NAFTA region.
· Launched three major start-ups, each involving $25M+ facilities with innovative processes and staffing configurations. All three were on-time, on-budget and injury free.
· Led the safe closure and integration of 3 manufacturing facilities with no reduction in customer service level.
· Provided formal and informal mentoring to new-hire engineers and junior managers.
· Experienced in GMP/FDA and Military Spec plants.
· Achieved impressive improvement in the areas of quality, productivity, safety and cost reduction for the last 15 contiguous years.
· Early adopter of Lean Manufacturing, Kaizen, 5S, Six Sigma and Behavior Based Safety.
· Implemented planned cultural change program in two acquired sites to achieve dramatic improvements in safety, quality, productivity and housekeeping.
· Developed and implemented 6 bottom-to-top re-engineering efforts to deliver capacity increases of 60% - 100%.
· Implemented a new quality model to raise first-time quality by 100%.
· Guided the implementation of enterprise resource management software (SAP) and a new MRP model to deliver increased on-time delivery and double-digit reduction in material inventories.
· Chief design engineer for the successful research/start-up/optimization of one of the world's largest aerospace carbon fiber plants with a capital project cost of $25M.
· Guided the development and introduction of innovative dispensing systems in coatings and automotive catalysts businesses.
· Used expert level programming skills in SQL, Access, Visual Basic, PHP, and HTML to develop various systems to leverage data for business improvement.
· Developed innovative process monitoring software and the associated plant management techniques based on the theory of constraints resulting in 70% increases in batch productivity. The system was cross-licensed and marketed to paint companies in the U.S.
· Patent Pending holder of innovative method for raising safety awareness through daily email safety messages.
EXPERIENCE SUMMARY details next section
10 - Site
Manager, Hexcel Corporation, Decatur AL
General Manager for all a large chemical facility making intermediates for the
aerospace and wind power composites industries.
07 - 10 Site
Manager, BASF Catalysts, Huntsville AL
General Manager for all functions of a vehicle and stationary catalyst
manufacturing and product development operation.
03 - 07 Site
Manager, BASF Corporation, Decatur AL
General Manager for all functions of a large industrial coatings manufacturing operation.
95 - 03 Site
Manager, BASF Corporation, Morganton NC & Grand Rapids MI (‘95-‘99)
General Manager for all functions of a multi-plant site making automotive and
industrial coatings.
94 - 95 Production Manager, BASF
Corporation, Morganton NC
Production Manager for automotive and industrial liquid coatings plant.
85 - 94 Senior Process/Project Engineer,
BASF Corporation, Rock Hill SC & Morganton NC
Chief engineer for design/implementation of new process technology for
aerospace carbon fiber production. Process and project work at the Morganton
plant.
81 - 85 Process/Project Engineer, Abbott
Laboratories, Rocky Mount NC
Engineer for design/installation of FDA regulated sterilizers, filling
equipment and distilled water generation for IV drug plant. Trained in GMP and
FDA certification process.
78 - 81 Co-op Design Engineer, BMA
Consultants, Raleigh NC
Design engineer for HVAC and process piping for institutional buildings
EDUCATION
04 - 07 M.B.A. Gardner-Webb University, Boiling Springs NC
76 - 80 B.S. Mechanical Engineering, North Carolina State University, Raleigh NC
OTHER SKILLS & AFFILIATIONS
· Chairman, Manufacturing Committee, National Paint and Coatings Association, 2005 - 2007
· Editor and Owner, dailySAFETYmessage.com
· Expert level in Office, Access, SQL, Visual Basic programming, Web Design, PLC programming.
· Intermediate level in Java programming, Linux, web server administration, SAP, network management.
· Graduate of Manchester Pro Coaching executive leadership program with high marks in coaching and strategic thinking
07 - Site Manager, BASF Catalysts, Huntsville, AL
· Led turnaround of an acquired manufacturing site achieving 50% productivity improvements and lowering cost 25%.
· Reduced injury rates by 70% using behavior-based safety programs based on peer-to-peer observations.
· Halved scrap generation rates and dramatically improved precious metal control.
· Led support of global manufacturing with engineering and manufacturing expertise in South Africa, China, India and Brazil. Mentored site managers at these sites on continuous improvement programs.
· Led product develop group for new product introduction at global manufacturing sites.
· Installed an innovative Customer Welcome program that uses plant operation tours and hospitality as a sales tool.
· Oversaw the start-up of $25M new line and a $15M per year capital budget.
· Led the 500 person Huntsville site with the mission of local manufacturing of automotive and heavy equipment catalytic converters
03 - 07 Site Manager, BASF Corporation, Decatur AL
· Led turnaround of an acquired manufacturing site realizing extraordinary gains in all areas in only 24 months. Delivered 60% batch productivity gains while reducing costs 25%.
· Reduced injury rates by 80% using behavior-based safety program based on peer-to-peer observations.
· Reduced Cost of Poor Quality by 37% through error control, poke yoke, Kaizen events and operator & supervisor coaching.
· Created various cultural change initiatives resulting in dramatic improvements in quality, safety, housekeeping and morale. Extensive face-time with plant personnel through “walking around” and 35 communications meetings per year.
· Fostered striking improvement in Sales and Manufacturing relationships through open, extensive communication. Hosted over 20 customer visit utilizing the plant as a sales tool.
· Directed the formation of a quarterly Technical Exchange program facilitating improved cooperation and relationships among plant and design technical groups.
· Rejuvenated employee recognitions and celebrations. Held an employee event every month including, cookouts, ice cream events, off-site picnics and holiday safety dinners.
· Increased dispersion in-spec rate to 99%, up from 85%, while executing the successful transfer of dispersion products from a sister plant.
· Relocated the Color Formulation group from facilities in Ohio and delivered a doubling of productivity in the number of color formulations per person.
95 - 03 Site Manager, BASF Corporation, Morganton NC, Grand Rapids MI
· Led project to build and start a $25M powder coatings plant. Project was injury free, on-time, on-budget, and on-quality. The new plant is based on self-directed high performance work teams.
· Dual site responsibility for Grand Rapids MI and Morganton NC site from 1995 – 1999. Led the closure team in transferring the products from Grand Rapids to Morganton and later the closing and decommissioning the Grand Rapids site.
· Reduced emissions by 40% while increasing production to maintain EPA true-minor source status.
· Led the team for transferring products from the Brantford Ontario site.
· Established and led a Community Advisory Panel for the local area.
· Guided the on-time, on-budget implementations of ISO 9000, QS 9000 quality registrations and the ISO 14000 environmental management registration.
· Implemented a behavioral safety system to reduce injury rates by 75% and severity rates to zero. Program focuses on the day-to-day behaviors that often result in injury.
· Increased productivity 60% by absorbing volume from three former plants without increasing headcount or fixed costs and without significant capital investment.
· Initiated and conducted a site process optimization that led to numerous improvements. This was a bottom-to-top total re-engineering effort.
· Developed a monthly program of individual coaching for the plant management team. Held annual seminars to teach leadership skills.
· Designed and programmed a production batch tracking database. The system allows supervisors and managers to optimize the number of batches in process and eliminate bottlenecks. This was cross-licensed and marketed to paint companies in the U.S.
94 - 95 Production Manager, BASF Corporation, Morganton NC
· Increased first-time quality 100% by implementing new quality model based on in-process testing rather than final inspection.
· Developed a culture of continuous improvement by measuring key performance indicators and implementing action plans to drive improvement.
85 - 94 Senior Process/Project Engineer, BASF Corporation, Rock Hill SC, Morganton NC
· Guided the R&D, design, installation and optimization of the world’s largest carbon fiber production line. Responsible for all phases of the 4000ºF conversion process.
· Developed process definition through the use of Design of Experiments and advanced statistical methods.
· Optimized production processes to increase line capacity by 50%.
· Designed and programmed an Oracle SQL based laboratory information management system. Included on-line data acquisition from lab instruments and over 50,000 lines of program code.
81 - 85 Process/Project Engineer, Abbott Laboratories, Rocky Mount NC
· Designed and installed new processes related to manufacture of IV drugs including FDA regulated sterilizers, filling equipment and distilled water generation.
· Conducted numerous upgrades and certifications of sterilizers and IV drug filling equipment.
· Reduced cycle times by 25% for intravenous drug sterilizers via automation.
78 - 81 Co-op Design Engineer, BMA Consultants, Raleigh NC
· Increased engineers’ efficiency by programming a computer aided design package to automate HVAC calculations.
· Designed energy management systems for utility savings at hospitals and university facilities.