Keith Mallard Email & Phone Number

Raleigh-Durham-Chapel Hill Area

Oxford, North Carolina, United States

Managed team of four bulk planners/schedulers in daily operation of planning and scheduling of liquid and powder chemical raw materials through pre-weigh through bulk processing for delivery to filling and assembly teams in a GMP facility. Ensured on-time delivery of bulk to finished goods team, delivered on safety and quality measurables, and managed inventory costs. Reported performance to plant management of KPI weekly and monthly with effective oral and written communication skills, using MS Word, Excel and PowerPoint. Collaborated cross-functionally in reviews, meetings, Kaizens, and root cause analyses with plant leaders from quality, manufacturing, bulk processing, central weigh, finance, R&D, product development, shipping and receiving, and IT for purpose of reviewing KPI and improving gaps in performance. Made effective timely decisions for process improvements and cost savings based on detailed analysis of data.Managed performance to schedules and project timelines, using crisis management, root cause analysis and corrective action, and process improvement. Decided where to manufacture new bulks based on capacity and constraints of bulk processing resources. Escalated risks in supply of bulk to internal customers and worked with raw materials team, bulk processing, and FG planning team to mitigate risks. Coached bulk planner to advancement. Recruited, interviewed, and trained replacement. Created product supply review for bulks to communicate risks in supply to FG planners. Worked with third party manufacturers on delivery and receipt of chemical raw materials and finished bulks. Shipped finished bulk products, some drug actives, to other Revlon facilities globally.

Oxford, North Carolina, United States

Recognized as supply chain representative for bulk processing on launch team for company’s conversion of ERP / MRP system to SAP ECC. Defined local business requirements for supply chain management. Identified gaps existing between working SAP template and local business requirements. Collaborated with SAP IT design team to create system to meet needs of company’s supply chain. Oversaw acceptance testing. Prepared and validated master data. Designed, executed, and managed superuser and end user training. Validated end user readiness on use of new system. Served as key user post launch, continuing to assist planning team. Made improvement recommendations, tested, and implemented improvements to system while performing manager role.

Oxford, North Carolina, United States

Multi-level planning and scheduling of FG, including sub-assembly and bulk processing for powder and mascara technologies to meet customer demand using MRP and Excel spread sheets. improved customer service levels for assigned technologies to meet internal and external customer needs. Delivered new product launches and phase in changes on time. Procured necessary materials and components from vendors on time to support production plans. Managed purchase to pay process, negotiated blanket POs and terms in addition to spot buy PO, and managed supplier quality and delivery performance for assigned domestic and international vendors. Delivered plan to F&A, which minimized changeovers and maximized schedule compliance and adherence while achieving delivery targets in the shortest possible manufacturing lead time. Dispositioned Slow Moving, Obsolete Materials and Rework in timely manner to meet inventory targets. Managed safety stock and cycle stock inventory levels for assigned technology to target. Utilized rough cut capacity planning to identify constraints and ensure F&A’s ability to execute future production plans. Coordinated with Customer Logistics Team on order fulfillment and timing. Escalated and mitigated risks associated with delays and shortages to domestic and international customer orders. Collaborated cross functionally daily with distribution, warehouse, production, quality, marketing, R&D, and demand planning. Maintained item master data in ERP systems for accurate planning and scheduling.

Roxboro, North Carolina, United States

Responsible for shipping, receiving, inventory control, indirect stores, and warehouse material handling of high-volume Tier 1 LEAN automotive supplier. Managed two exempt logistics facilitators and 70 indirect material handlers. Recommended disposition of excess and obsolete inventory. Scheduled indirect labor to support weekly production schedule within budgeted spending. Developed and implemented corrective actions for safety, quality, and delivery issues. Designed and managed material flow through 3PL. Negotiated with vendors, suppliers, and plant service providers to expedite delivery and control costs. Expedited freight to automakers domestically and internationally.• Conducted year-end physical inventory of $17,000,000 inventory with less than 1% write-off.• Established method for Just-In-Time delivery of raw materials with 3PL, reducing on-site inventory levels to 12 hours of production pull rate.• Maintained greater than 98% inventory accuracy of over 2,000 SKUs.• Closed 125,000-square-foot warehouse according on time using project management to save money.• Improved material flow and reduced inventory levels throughout plant with timed delivery routes, flat storage, and visual signals, using Kaizen blitzes, value stream mapping, and continuous improvement tools.

Roxboro, North Carolina, United States

Directed entire assembly operation of high-volume Tier 1 LEAN automotive manufacturer. Managed team of six exempt production facilitators and 275 direct assembly associates across three shifts. Supervised assembly operation to exceed budgeted expectations for safety, quality, delivery, productivity, and cost. Built assembly teams through hiring decisions and coaching. Developed weekly production plan to meet customer demand within budgeted spending levels.