Director Of Plant Operations
Batesville, Indiana, Us
Direct site management including development of Human Resources, Quality, Engineering, Lean, Operations, EH&S, and Finance team members to strongly influence on the plant performance. Full budget and P&L responsibility. * Awarded “Lean” and “Safety” plant of the year. * Successfully reduced union grievances to 30 per year, from a previous high of 500+ per year through education and daily directional involvement. * Saved company $1.4M in labor costs by drastically reducing weekend production and overtime. * Implemented Poka-Yoke devices across the plant, which greatly reduced mistakes and product defects.* Led Kaizen efforts to reduce scrap by $50,000 a month. * Intensive customer interaction for strong relationships.* Utilized “glass walls” to visualize Key Process Indicator Performance for team member ownership. * Successfully reduced cost of monthly Work In Process inventory from $1.5M to $1.1M.* Identified a product defect that affected $60,000 of manufactured product; redesign with new material, resulting $1M+ in material savings. * Developed Electronic Kanban resulting in reduced inventory and faster fulfillment times.* Improved on-time shipments from 97% to 99.9%.