Charles Morley Email & Phone Number

Operations Consulting and process improvement

Twinsburg, Ohio, Us

Vice President of Manufacturing OperationsManaged full P&L for manufacturing sites in North America. Direct reports include site managers and functional department leads. Design, quote and implement new products. Consolidated two plastic extrusion facilities. Implemented new ERP system at manufacturing sites. Metal forming, bending, stamping, powder coating, welding and electromechanical assembly.• Achieved cost savings of $3M in first 9 months by implementing automated welding, metal forming and powder coating and efficiency metrics • Implemented visual management for capacity planning to help Customer Service enabled OTD to increase from 82% to 98%. • Changed plant management structure to enable implementation of Lean and improve SQDC metrics and reduce employee turnover.• Created 3 year strategic plan for manufacturing and company growth which allowed Siffron to capture an additional $20M in sales to their largest customers.• Created new scheduling system inside the ERP system and improved the reporting structure of the production floors at each of the factories. This improved scheduling accuracy and reduced lead time by 30-50% in several cases.

Northbrook, Il, Us

Manage: Safety, Quality, Supply Chain, Logistics, Operations, Customer Service, ITConsolidated three warehouses into one. Moved company to new expanded and upgraded headquarters. Implemented 5S and One Piece Flow. Upgraded and manage IT system at new site. Created changes to the ERP system so we went from less than 30% usage of IQMS (ERP system) to more than 80%. Implemented lean across the entire company and created U shaped cells on the manufacturing floor.• Improved OTD from 76% to 97% while improving standard lead time to 5 days or less. Used one piece flow in Assembly, Warehousing and Customer Service to achieve this.• Improved quality from 86% to 98% in the past year by implementing training programs and error proofing.• Achieved over $1.5M in savings in 2015 due to resourcing of product, negotiations with current suppliers and reductions in complexity of supply chain.• Electrical and Electronic manufacturing with electromechanical assembly and testing. Sheet metal fabrication, CNC machining and powder coating.Recommendation by CEO John Ranshaw: had the opportunity to work with Charles for 4 years at CONTECH Lighting. During this time Charles was responsible for all of CONTECH's global supply chain and daily operations including customer service, manufacturing and warehousing. During this time Charles made many significant contributions to the organization including overseeing construction and relocation to our current 200,000 sq foot facility. Charles was also responsible for effectively introducing LEAN principles to all areas of the organization with measurable improvements in performance and efficiencies. Charles has the quiet confidence of a true leader and has successfully built a strong team of direct reports. After CONTECH's acquisition by Leviton, Charles took on additional management responsibilities for all of Leviton's worldwide lighting companies. I would recommend Charles for any positions (including COO) without reservation.

Waukegan, Illinois, Us

Direct reports included Design Engineering, Manufacturing, Logistics, Distribution, Quality, Safety, Lean, Supply Chain, Manufacturing Engineering.Promoted into VP role that managed Design Engineering and Operations. Managed quality, design engineering, manufacturing engineering, production, distribution, purchasing, global sourcing, logistics and safety for 4 manufacturing sites and 3 distribution warehouses. Supported new product development and cost reduction. • Restructured engineering to improve output of new products by 50% and which resulted in growth of commercial market by 30%.• Implemented Strategic Goal Deployment, SQDC

Waukegan, Illinois, Us

Electrical and Electronic manufacturing with electromechanical assembly and testing. Sheet metal fabrication, CNC machining and powder coating.• Improved OTD from 59% to 86% in 3 months by implementing true Kanban system rather than spreadsheet Kanban and implementing metrics that measure total OTD. • Achieved approximately $316,000 annual savings through Lean Methodologies implementation. • Implemented cost savings of $386K in Logistics by changing logistics provider in SE Asia. • Achieved $512K in cost savings by focusing on cost reductions with top 5 key commodities.

Downers Grove, Illinois, Us

Managed production, purchasing, building maintenance, shipping and receiving, and safety. Manage 8 direct reports. Support new product development through management of select NPD teams and manufacturing engineering support of all NPD projects. Create annual budgets and 5 year strategic plans. Use leadership skills to motivate team.• Reduced quality issues by 50% for external, supplier and internal defects by implementing, Shingo Zero Quality, daily quality countermeasures, 5 Whys and PDCA. • Improved OTD from 36% to 100% in 3.5 years. This was achieved by implementing lean tools: 5S, Standard Work Kaizen, one piece flow, build to order, level loading, Kanban (internal and external), VMI and Consignment programs.• Improved inventory turns from 2.99 to 8.89 in three years. Trained purchasing team to implement Kanban, VMI and Consignment for raw and finished materials.• Implemented Kaizen, 5S in production and throughout all of the departments. Cost savings of $1.4M through Kaizen improvements and Kaizen Blast program.• Setup controller assembly line at OPW China facility and OPW Brazil facility. • Saved $197,000 in 2008 through negotiation, process changes and competitive bidding•Electromechanical assembly, wire harness, PCB manufacturing, sheet metal fabrication and CNC machining.

• Improved productivity on BX production line by 50% by implementing standard work and one piece flow. • Used Kanban and Standard work to combine three work cells into one and improved productivity by 33%.• Responsible for Kaizing production line of new acquisition and then moving the nozzle production of that company to Videojet. During the Kaizing process, improved OTD by 30%, LT by 70% and quality by 50%. • Implemented raw goods and finished goods supermarkets in nozzle lab and BX area to improve on-time delivery and ensure there are no stock outs. Nozzle lab delivery was 100% after implementation of supermarket.

• Rebalanced assembly line to improve productivity 30%Implemented cost savings of sheet metal cabinets $140K annually• Increased productivity in VJ Printer Refurb by 150% by implementing one piece flow and production cell layout. • Increased quality of nozzle by 65% by working with molder to reduce contamination during molding of and storage of Ryton parts.• Managed cost savings projects totaling $500,000 by changing the gauge of the steel used, removing unnecessary welded areas and other sheet metal and molding improvements.• Coordinated consolidation of Elkhorn and Wood Dale facilities. Compressed layout of Wood Dale facility by 60% to open up 70,000 square feet for Elkhorn facility.

Master Of Business Administration - Mba, Operations Management, Marketing, Organizational Behavior

Master Of Science - Ms, Mechanical Engineering

Bachelor Of Science - Bs, Mechanical Engineering