PROFESSIONAL EXPERTISE

PROVEN LEADER

·     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 50% productivity gains while reducing costs 25%.

·     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 two major start-ups, each involving $25M+ facilities with innovative processes and staffing configurations.

·     Led the safe closure and integration of 2 manufacturing facilities with no reduction in customer service level.

·     Provided formal and informal mentoring to new-hire engineers and junior managers.

·     Experienced in GMP and FDA regulated plants.

CHANGE CATALYST

·     Achieved impressive improvement in the areas of quality, productivity, safety and cost reduction for the last 12 contiguous years.

·     Early adopter of Lean Manufacturing, Kaizen, 5S, Six Sigma and Behavior Based Safety.

·     Implemented planned cultural change program in an acquired site to achieve dramatic improvements in safety, quality, productivity and housekeeping.

·     Developed and implemented numerous bottom-to-top re-engineering efforts to deliver capacity increases of over 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.

INNOVATOR

·     Chief design engineer for the successful research/start-up/optimization of $25M world's largest aerospace carbon fiber plant.

·     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.