Experienced and proven leader with a rich mix of operations, finance and business developent knowledge for a global expanding business. Has extensive history of improving all aspects of operations performance by applying continuous improvement initiatives, transformational process technology changes and developing key partnerships with internal partners, customers and key suppliers. Extensive expertise in highly complex product mixes, technologies and customer requirements.
Skill Highlights
Strategic Planning Manufacturing Contingency Lean Six Sigma Operational Excellence Capital Management Continuous Improvement Labor Negotiations Safety and Environmental Supply Chain Process Safety Management Supplier Quality SQC/SPC/Process Capability
Core Accomplishments
Professional Experience
Global Director of Manufacturing, 09/2010 to Current Bickford Senior Living – Bloomington, IL,
Responsible for all colorant manufacturing locations globally for business that exceeded 150 MM in revenue in 2014.
Full P/L responsibility with focus on cost center performance and overall cost reduction initiatives.
Led all initiatives to improve safety, quality, and productivity with alignment to strategic business plan.
This business supplied key colorant raw materials to Valspar's paint and coating business with revenue exceeding $2.5 Billion.
SAFETY Improved OSHA TRIR injury rate for North American facilities to world class level of 0.75 with focus on key leading indicators, employee engagement, and sustained learnings.
Reduced spill incidents for all site by 25% for years 2011 to 2015.
Improved corrective action closure to 90% on time by utilizing 5 Why Methodology and TapRoot root cause analysis.
QUALITY Reduced Cost of Poor Quality for global manufacturing to less than 1 % by using Lean Six Sigma, improvment teams and improving overall process capability.
Led the development of a rigid supplier raw material quality process that focused on eliminating the need for pretesting of raw materials while improving supplier acceptance rates Utilized SPC/SQC to improve overall problem batch rates by 50% from 2013 thru 2015.
Instituted standardized QC processes globally to support manufacturing contingency capability.
COST/PRODUCTIVITY/SERVICE Utilized Six Sigma to improve North American productivity from 320 lbs/mn-hr to 525 lbs/mn-hr while increasing product mix complexity by 100%.
Reduced manufacturing conversion cost by 35% from 2011 thru 2014.
Executed operational stratgegy that allowed the business to grow revenue an average of 15% from 2011 thru 2014 while improving operating profit by 31% during the same time frame.
Improved service On Time - In Full to 98.5% by instituting supply chain and global inventort strategies for finished goods and raw materials.
Developed key global contingency strategy to balance plant capacities during peak demand periods.
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Developed and implemented key operations strategy with a focus on new process technology, globally standardized processes and process control/automation.
Standardized milling technology and manufacturing processes so that business could leverage global capacity and contingency.
Utilized Lean Six Sigma to develop innovative quality control color measurement eqiupment that reduced test variation by 200% and reduced QC cycle time by 75%.
Implemented joint development projects with key equipment suppliers to transform manufacturing processes such as continuous processing from batch.
Designed, built and started China facility that mirrored manufacturing facility of North America.
Worked directly with key pigment raw material suppliers to develop new and improved pigments that improve internal manufacturing process capability.
Established Milling Center of Excellence and jointly developed Valspar Disperson Academy with key supplier technical support.
Site Manager, 11/2000 to 09/2010 Novolex – Yakima, WA,
Responsible for overall operations at facility that included manufacturing and R&D.
Led all initiatives to improve safety, quality and productivity.
Improved site safety culture and achieving a TRIR of less than 1.
Led and instituted an employee behavioral based safety program based on hazard recognition and employee engagement.
Led key business and operations initiatives that grew site volume 6 fold from 2001 thru 2010.
Led productivity and capacity improvements that allowed business to internalize 95% of Valspar's external industrial colorant purchases.
Led the team that achieved ISO 9001 certification in 2007.
Reduced site conversion cost an average of 15% per year by improving productivity thru batch size optimization and key milling process improvements.
Improved sites material efficiency to +99% thru improved process and formula capability, process standardization and formula optimization.
Plant Manager, 04/1998 to 09/2000 Flint Ink Corp./CDR Pigments And Dispersions – City, STATE,
Site manager for CDR Pigments and Dispersions largest manufacturing facility manufacturing organic pigmentsand dispersions for ink industry.
Site revenue of $130 MM with volume of 40 MM pounds of organic pigment and dispersion.
Instituted key safety management system with emphasis on safety standards and reduced plant TRIR from +20% to 2.5 in less than 2 years.
Utilized Lean Six Sigma MGBB project to improve overall quality and cycle of high volume product in plant and delivered a $4MM savings.
Instituted key process automation strategy for organic red pigment manufacturing that reduced cycle time and delivered a 20% improvement in capacity.
Developed joint venture with key equipmenty supplier to convert traditional batch process over to continuous process and improved capacity by 100%.
Led the design and installation of a reverse osmosis ultra-filtration waste water treatment plant that took plant to zero discharge from 700,000 gallons/day of discharge.
Education
MBA: , Expected in 2013 University of Phoenix - , GPA:
Bachelor of Science: Chemical Engineering, Expected in 1986 University of Kentucky - Lexington, KY GPA: Chemical Engineering
Additional Information
Additional Information
ACCOMPLISHMENTS President's Award for Environmental, Health and Safety Excellence Years 2008, 2009, 2010 and 2012
RECOGNITIONS Valspar Elite Award : 2008 Valspar Award of Excellence : 2007 and 2012
Skills
automation, balance, business plan, color, Continuous Improvement, conversion, cost reduction, focus, frame, hr, ink, ISO 9001, manufacturing process, manufacturing processes, materials, 98, Negotiations, optimization, paint, peak, process control, processes, profit, QUALITY, quality control, SAFETY, Six Sigma, SPC, strategy, strategic, Strategic Planning, Supply Chain, technical support, water treatment
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