Operations Leader (235539) West Point BSME, Green Belt / Foundry, Casting, Injection Molding, Packaging, Blending, Assembly Operations / Single and willing to relocate
Exceptional Operations Director and a degreed engineer with 10+ of experience directing operations across countries and continents through channel development, savvy P&L management, cohesive internal team development, and process improvements. He is a BSME graduate of West Point Military Academy and was a member of the US Army Airborne and Ranger Regiment. He is also a Six Sigma Green Belt. He has taken these disciplines to improve operations, achieve production records, reduce costs, and exceed EBITDA targets for his employers.
He is a confident and strong communicator who is skilled with deploying leadership and management training for succession planning, operational improvements, and staffing up organizations in manufacturing, industrial, and military officer settings. This Game Changer’s work history includes Operation management for an aluminum recycling foundry where they cast ingots and sows.
He is currently employed as an Operations Leader but is interested in confidentially exploring the new leadership roles. His skills, education, and accomplishments make him a welcome addition to any manufacturing leadership team. He is single and willing to relocate for the right opportunity. His notable history includes:
• Metal Mold Casting aluminum ingots and Sows
• Responsible for Production, and Shipping & Receiving departments.
• Turned a plant that had a $500k loss in June 2020 into a profitable entity.
• Orchestrated transition from three shifts of eight hours 5 days a week to a 24-7 schedule in 4 weeks.
• Downscaled production from four shifts to three, to limit the idling of furnaces when labor shortages emerged.
• Increased pounds per labor hour by approximately 40% in 2020-2022.
• 2021 EBITDA was 19% over forecast. By August 2022, achieved 172% of forecasted EBITDA.
• Achieved record month in May 2022 with a three-crew staffing with 15.37M lbs. produced.
• Achieved new one-day records of 700k and 800k lbs. from previous high of 600k in 2019.
• Increased compliance with safety training resulting in 100% completion for 2020 and 2021.
• Significantly revised Dryer operator preventative maintenance checklists, which resulted in a 36% increase in OEE.
• Developed custom Excel tool to determine Dryer activity based upon monthly production goals resulting in 100% of production needs met.
• Developed program to monetize scrap roll off containers which yielded thousands of dollars.
• Reduced cost of goods sold (COGS) by 25.7%
• Increased number of pieces produced by 45.6% with 30% less staff.
• Reduced production scrap daily average by 65.7%
• Reduced work in progress (WIP) by 98.1%
• Reduced raw stock inventory by 68.8%.
• Reduced finished goods inventory by 45.6%.
• Increased order shipment velocity by 65.9%
• Foundry Operations
• Refractory Furnaces
• Rotary Furnaces
• Metal Mold Casting
• Assembly Operations
• Forming Operations
• Thermoforming Operations
• Injection Molding Operations
• Blending Operations
• Cell Manufacturing Operations
• Batch Manufacturing
• MOC Management of Change
• Creating SOPs
• Calculating Production / Labor/ Material Costs
• Continuous Improvement Projects
• Process Optimization
• Process Troubleshooting
• Data Collection / Analysis
• Creating/Implementing Operations Metrics
• Using Visual Systems
• Running Operations on Metrics
• Driving Cost Reduction
• Ensuring Future Material Availability
• Ensuring Optimal Inventory
• WIP Inventory Management
• Inventory Controls
• Adjusting Production Schedules
• Materials Management
• Meeting Manufacturing Delivery Targets
• Increasing Production Capacity
• Increasing Throughput
• Reducing Scrap
• Holding Kaizen Events
• Holding Kanban Events
• 5S / 6S Methods
• Implementing Lean into Manufacturing
• CMMS
• Prioritizing Jobs
• Holding Staff Accountable
• Production Planning
• Identifying Capacity Requirements
• Preparing Production Schedules
• Controlling Labor Costs
• Scheduling Materials / Labor
• ERP Systems
• Improving Manufacturing Processes
• Developing Cost Effective Processes
• ISO Documentation
• HS&E
• OSHA Regulations
• ISO 9001
• Root Cause Analysis
• Maintaining Production Paperwork
• Managing Multiple Projects
• Order Status Reports
• Plant Maintenance
• Preventative Maintenance
• Resolving Production Bottlenecks / Problems
• P&L Responsibility
• Giving Performance Reviews
• Process Safety Management
• Team Leadership- 4 direct /85 indirect
Education / Certifications
• BS, Mechanical Engineering / United States Military Academy, West Point, NY.
• Six Sigma Green Belt – Real Alloy
• Lean Certified