Nicholas Wall Email & Phone Number

Gig Harbor, Washington, United States

Gig Harbor, Washington, United States

Held full P&L responsibility for all manufacturing functions within a $130 million operation. Led management team of 4 and reported to the company president. Directed all plant upgrades and new technology implementations to improve productivity, quality, and service performance. Oversaw Safety Program and Certified Forklift Training Program for all locations. Challenged to standardize metrics and goals across all locations with different management styles, labor forces, and market/customer demands.KEY CONTRIBUTIONS & ACCOMPLISHMENTS: Drove $20 million inventory reduction in 2009 and controlled/cut manufacturing costs during down period in the national construction industry, including a $1.3 million cost reduction while leading a $600,000 Recycling department. Spearheaded $1.5 million Anchorage, AK plant upgrade that reduced natural gas consumption 20%, raised productivity 300%, decreased inventory 70%, cut labor costs 35% (eliminating one shift and weekend production runs), and expanded production capacity 200%. Decommissioned and relocated 3 facilities, setting up equipment at other plants that increased productivity/throughput at all locations and consolidated production volumes. Developed Preventive Maintenance System using off-the-shelf software that led to a 30% downtime reduction and the introduction of a centralized spare parts inventory for all major equipment pieces. Played key role in Insulfoam’s position as the leader in environmental compliance by monitoring compliance performance, including wastewater/stormwater discharge and VOC air emissions, with production limits tripling over a 10-year period.  Created production metrics program to achieve consistency across all locations, evaluating output and impact of product mix on throughput; implemented shop floor computer system rollout.

INSULFOAM (division of Premier Industries) – Tacoma, WA – 1993-2007Vice President of Manufacturing, 1998-2007Directed all operations for 13 U.S. facilities ($170 million in total sales and 670 total employees). Identified and instituted best-in-class manufacturing practices across all locations. Restructured decentralized business units into a centralized, cohesive whole that included standardized quality control testing, purchasing, inventory control, paperwork, costing, and production efforts.KEY CONTRIBUTIONS & ACCOMPLISHMENTS: Captured $9 million in savings on $97 million in purchased raw materials (in 2006); reduced costs 20% and improved laminated products’ performance through new tri-layer film. Led installation of new automated equipment within all locations, including new plant layout designs, that resulted in 20-200% productivity increases (due to equipment standardization) and decreased downtime. Contributed to the purchase of 2 operations in SC and FL as a member of the Acquisition Team, with acquisitions filling void in the company’s national presence and increasing annual sales by $14 million as well as securing both Home Depot and Lowe’s as national customers. Redesigned plant flows for SC, FL, and CO facilities that led to standardized production flows into purchased facilities, environmental compliance updates and subsequent 200-300% production capacity increases, and increased brand awareness through capability and serviceability expansion. Designed, constructed, and initiated start-up of OH and TX facilities that targeted servicing of niche markets for the insulated garage door business, solidifying Insulfoam as a leader in the niche market and utilizing JIT services to supply the top 2 garage door suppliers in the U.S. (generating sales of $15 million).

National Sales-Introduced and sold specialized insulation products to multi-location customers• Developed specialized laminated insulation sales with Home Depot and Allied Building Products• 300% increase in sales revenue from West Coast, including Alaska, Home Depot stores

Site Operations Manager- Operational and financial responsibility for company’s first combined multi-business location (Premier Panels, Insulfoam, and Premier Packaging) $7MM sales with 130 employees • $20MM future product line R&D (Poly-Laminated Rigid Expanded Polystyrene)• Designed and built new Insulfoam and Premier Packaging manufacturing facilities at site• Trained new management team to run the operations• Optimized use of location’s fleet of semi-trucks by creating service zones and a trailer drop program • Developed best practices to minimize scrap and increase quality; standardized resin types and densities to maximize profits

Division Operations Manager- $6.4MM sales, two location business focused on specialized molding of protective packaging for perishable foods and electronic components• Restructured two underperforming EPS molding facilities in Kent, WA and Dixon, CA. • Utilized lean manufacturing and optimized product flow to increase productivity by over 200%• Upgraded plant equipment and utilities to reduce processing costs by 27%• Decommissioned several competitor plants and consolidated equipment and customer sales ($3 million) into a single operating location• Designed new signature mold for company’s Insulated Concrete Form• Developed new techniques for creating colored coolers for sales to Fred Meyer • Implemented division wide safety program with monthly meetings addressing targeted areas and safe practices in the work environment