Gerald Rust Email & Phone Number

Melbourne, Vic, Au

Melbourne, Victoria, Australia

Newark, California

- Led Profit improvement activities. This included labor efficiency improvements, scrap and NRFT reduction, and floor space utilization improvement. Improvement of Plant EBITDA was a key focus during this time. Savings of more than $2 million were achieved every financial year.- AMS (Adient Manufacturing System) deployment, specifically the principles of Value Stream Flow and CI Culture. VSF achieved a level 3 rating after once year and CI culture achieved a level 2 rating.- Eliminated 100% of forklift traffic in production environments, thereby contributing to a significant reduction in safety incidents.- Reduced scrap in headliner forming area from $60 000 to $20 000 per month- Led 5S activities throughout the plant. The plant 5S score went from 60 to 80+ percent.- Conducted monthly Kaizen events, which contributed to the Profit improvement plan.- Introduced a Rewards and Recognition program.- Lead improvement of MES / JIT system including customer driven changes. Implemented an electronic replenishment system form the customer, thereby improving on time delivery from 95 to 99%.- Warehouse consolidation. This led to a 20% reduction in floor space requirements.- Led rebranding activities when Futuris was sold to Adient.

Newark, California

- Expanded a team of Process & Controls Engineering, Maintenance and Facilities, growing the team from 9 to 18 members in line with growth of the business.- Launch of Tesla Model X vehicle and Karma 1.0 production lines. Responsible for process performance for seat assembly, frame welding, headliner thermoforming and assembly from prelaunch builds to SOP. Led ramp-up of Model X lines from 0 to 200 vehicles a day over a two-month period.- Alleviated capacity constraints during ramp-up.- Increased line efficiency during ramp-up from less than 50% to over 85%- Managed plant CAPEX which was over $2 million during this period.- Responsible for Repairs and Maintenance budget which affected the P&L- Developed a critical spares strategy for the entire plant.- Achieved TS16949 compliance- Monthly reporting for corporate KPI’s, such as OEE, PM adherence and 8D closures.

Edinburgh Park, Australia

- Responsible for Process and Quality Engineering. Managed quality performance through the supply chain including the customer, internal and the supplier base. - Maintained TS 16949 and ISO 14001 accreditation- Monthly reporting of corporate KPI’s, such as customer ppm. During this period, Futuris EP moved away from being a GM Top Focus supplier, by achieving less than 50ppm consistently- Maintaining and Improving GPS (Global Production System). The GPS score for the plant peaked at 82%, thereby being ranked the number one plant in the Futuris group.

Edinburgh Park, Australia

- Introduced processes for new products, starting with the quotation phase and seeing this through to launch and production handover. Products included seats, carpets, door trims, headliners and trunk trim for a new vehicle model. - Managing of project timelines, capital budgets and equipment procurement formed a key part of this role. - Responsible for the overall plant Capital budget which peaked at $4 million in 2013.- Managed 6 project engineers responsible for the introduction of new processes. - Secured government funding to introduce energy efficient US welding equipment and LED lighting, thereby reducing the carbon footprint of the factory by 4%.- Responsible for the site Safety Management System, maintaining a zero overdue hazards status.

Edinburgh Park, Australia

- Led the introduction of manufacturing processes for headliners and floor carpets for 2 new models.- Work included supporting quotation to the customer (plant costs), writing equipment specifications, managing equipment manufacturers, commissioning of equipment and full production handover through training of production team members. Total Capital budgets managed during this time were more than $ 500 000.- Led optimization of labour through line balance activities to meet quoted standard times. In all cases target times were either met or were less than the quoted times.

Edinburgh Park, Australia

- Production management and technical support at a newly purchased facility. Responsible for 25 team members.

Edinburgh Park, Australia, Melbourne, Australia

- Coordinated the consolidation and integration of two production facilities. This eliminated 25% of manufacturing floor space requirements.- Relocated a production line from Melbourne to Adelaide. Scrap was reduced from 10% to 2%. Headcount was reduced from 20 to 11 per shift.- Launched new door trim panels, both for the vacuum forming and assembly processes. - Implementation of an automated headliner thermoforming folding process. This led to a reduction in headcount of 5. Scrap was reduced from 5% to less than 1%.

Port Elizabeth Area, South Africa

- Planned, coordinated and controlled new business enquiries, product introductions, engineering changes and equipment / facility upgrades and installations. - Launched new product assembly lines for two customers. Customer milestones were all met.- Coordinated building of a new facility on a greenfield site, liaising with architects and builders daily. Despite a very wet season, all pre-launch milestones at the customer were met.

Port Elizabeth Area, South Africa

- Led the set-up of door panel production lines as per guidelines in the Faurecia Excellence System. During this period 4 product lines were launched with 3 different customers. All 4 launches had zero downtime at the customer.- Wrote a scope of work for the construction of a new factory building. - Supported the creation of specifications for the cockpit and front-end assembly lines designated for the South African operations.

Telford, United Kingdom

- Responsible for both the inbound and outbound logistics and Continuous Improvement at this JIT factory.

Bachelor'S Degree, Industrial Engineering

Diploma, Training And Assessment

Diploma, Project Management

Diploma, Business Adminstration And Management

Certificate, Lean Manufacturing