Mark Essig Email & Phone Number

Wilkesboro, Nc, Us

Engineering Leader for designing and manufacturing premium Engineered to Order Chemical Storage Buildings to meet the codes and regulations for Safe Chemical Storage.

Asheboro, North Carolina, Us

• Delivered leadership in Continuous Improvement, Quality Assurance, Manufacturing Engineering, Facilities, Maintenance, Sourcing activities, and Environmental Health & Safety that enhanced product quality, increased throughput, raised productivity, elevated safety, sales, and delighted customers.• Implemented a reverse logistics process for ecommerce sales that included return policy and procedure (RPP), remanufacture or refurbishment (ROR), and waste disposal (WAD) that improved cycle time by 45%, reduced processing cost by 33%, minimized waste creating a zero-landfill waste disposal process.• Prevented $100k+ per year of cost by managing the response and action plan for Facility Risk Management audits reducing annual premium by addressing facility deficiencies in less than 4 weeks.• Generated an Environmental Safety Program that included reporting, communication, training, OSHA compliance, and root cause analysis, reducing recordables by over 50% in one year.• Spearheaded Environmental Social Governess management and formed a cross-functional team to develop a scorecard and build action plan.• Increased throughput by 20% and decreased feeder department work in process (WIP) 50% in two months based off value stream map (VSM) findings and implementation into value streams.

Edgewater, Florida, Us

● Delivered a $50M expansion project, growing manufacturing footprint from 387,000 to 556,000 SF, supporting infrastructure, and tripling capacity in 3 years hitting timelines and on budget. ● Effectively led capital projects, vertical integration, and Advanced Manufacturing activities to improve supply chain, reduce cost, increase capacity, improve processes, and enhance information flow.● Collaborating with business stakeholders developed and championed the five-year capital plan.● Executed $30M+ capital budget, $2.4M utility budget, and $3.5M MRO budget annually.● Directed multiple projects, project scope, scheduling, sequencing, follow-through, timelines, project budgets, cash flow, internal & external resources allocation, and delivered stakeholder expectations.● Developed a mobile foam system to dispense foam with 48' arm and a 75' delivery arm system utilizing PFMEA, Risk Analysis, PPAP, DOE, Priority Matrix, and LSS tools. Project cost $9M.● Implemented an LSS project that decreased material variance by 20% and saved $200k per year by employing a material management system to give real-time feedback to operators and record usage. ● Delivered a data-driven approach to decision-making, prioritization, risk mitigation, budget preparation, resource allocation, schedule attainment, coordinated procurement, logistics, and disciplined change management.● Managed multiple projects/programs, project scope, scheduling, follow-through, timelines, project budgets, cash flow, analyzed data, internal & external resources allocation, and delivered stakeholder expectations.● Demonstrated leadership, cost management strategies, financial planning, best practices, technical expertise, vision, alignment, high standards, highly organized, coordination, and attention to detail.

Edgewater, Florida, Us

● Grew the ME department accountable for new product launches, product & process control, scrap reduction, and labor requirements into a support team focused on reliving pain of daily operations, improving labor efficiency and material variance in a fast-paced high-mix production environment. ● Transformed maintenance staff from a reactional group to an agile productive preventative / predictive team delivering maintenance, repair, installation, and service for facility, equipment, and grounds.● Achieved material scrap reduction of $250,000 per year by completing a green belt project by installation of CNC cutting equipment, tooling, CNC programs, process, and training in 6 months.● Reduced safety-related cost 125% and achieved 3.5 years without a lost time accident by driving awareness, reducing potential risks, promoting safety, and celebrating achievements.● Delivered a $9.8M fast track expansion project increasing manufacturing footprint to produce boats from 34 to 42 feet, bringing the total footprint from 285,000 to 387,000 square feet.

Edgewater, Florida, Us

● Lead team responsible for new product introduction, product enhancements, manufacturing processes, product quality, product drawings, process documentation, workstation breakdowns, elimination of waste, production support, improved safety, and on-time customer delivery. ● Realized savings of $3.5M by leading the manufacturing team in current state and future state value stream mapping to function as a high-level road map to the implementation of Lean. ● Successfully collaborated with product development integrated 4 new models per year and implementation of model year changes with 150+ enhancements across product lines.● Increased weekly throughput from 15 to 34 engineering changes per week while reducing the backlog of open changes to less than 30 days and a typical cycle time of fewer than 7 days.

Marktheidenfeld, Bayern, De

• Manage / direct all phases of new product introduction of an automotive including feasibility review, quoting, design, production process development, process documentation, process flow charts, control plans, PFMEA’s, work instructions, production part approval, customer submission, and release to production. New project implementation budget was $4 million annually.• Responsible for expendable tooling design, procurement, and budget of $1.5 million.• Implementation of over $500,000 in new un-budgeted cost savings.

Us

• Consolidated product offerings reducing number of SKUs from over 2,500 to less than 1200 SKU’s and rationalized machining and assembly of the products with resulting in an annual savings of $850,000.• Managed from design to construction of a $12 million facility completed on schedule and $400,000 under budget.• Managed capital expenditures growing from $2.0 to $4.5 million and MRO budget growing from $1.7 to $4.2 million annually. Including $800K powder coating paint system, $850K Trunnion machining center, $1.6 Million 16 station machining center and various other capital projects.

Munich, De

• Implemented work cells to supply production of fabricated parts. Improving on time performance from 80% to 95%, reducing WIP 66% and manufacture power panels reducing lead time from 8 days to 2 days.• Managed all phases of an $8 million manufacturing facility from design to construction then start-up. • Directed the relocation of the Dallas plant, sales office, and distribution center into a new facility then consolidated the Atlanta and Dallas plants increasing production 100% then decommissioned the old facilities.• Justified, specified, negotiated price, and implemented a new $1,020,000 powder coating paint system.

Us

• Start-up of operation of distribution gear production in the Seneca Plant. Developed work instructions, fixtures, Kanban, standard work, and layouts based upon best practices.• Supervised thirty associates during set-up, training, and start-up production of the switchboard line.• Developed/implemented a system to show departmental start dates, supplying schedule visibility, aiding in level loading, and determined standard labor for each product. Improving on time shipping from 65% to 90+%.

• Simplified the assembly and manufacturing of product through the implementation of single piece flow, layout, automated material handling, and production processes resulting in annual savings of $530,000.• Led the transfer of existing products to the Echlin Ponce, PR facility: including production training, project planning, equipment specification/procurement, plant layout, and part packaging. Annual savings $300,000• Replaced the labor-intensive task of manual heavy wire bonding with an automatic wire bonder, delivering improved quality, improved consistency, and a direct labor savings of $120k annually.