Manufacturing Manager

SUMMARY OF QUALIFICATIONS

Seventeen successful years in production supervision, plant safety,

manufacturing engineering, operations management, lean manufacturing and

demand flow technology, and continuous improvement resulting in several

promotions and roles of increasing responsibility. Aggressive and have a

"take charge/change agent" mentality and "can do attitude".

. Extensive lean manufacturing & demand flow technology experience using

Lean Production System principles to lead, participate and implementation

in formal lean manufacturing, Kanban, 5S's and kaizen activities with

solid change management skills and proven ability to create, educate, and

communicate the need for change.

. Ability to apply "Continuous Improvement" strategies across plant

functions, which includes the ability to introduce, needed change; create

excitement for change while leading the change initiatives. Adaptable and

open to new ideas

. Extensive experience in manufacturing processes; design and building of

tooling and fixtures, laser cutting, presses and forming, CNC precision

machining, welding robotics (ABB, OTC, IGM & Motoman) and automation

implementation, PLC programming, painting (wet & powder), fiberglass

winding, and high volume assembly; exceptional ability to re-engineer

processes/facilities

. Experience with Profit and Loss Responsibility as well as extensive

experience managing multiple areas within a manufacturing facility

combined with considerable supervisory experience

Provide daily support/leadership to insure that Manufacturing Operations,

Productivity and Quality objectives are met.

. Ability to refine communication skills based on their audience, use

active listening skills and non-verbal rapport building skills and

effectively communicate their message to both small and large groups

. Strong experience of consolidating/merge plants to achieve highest

operating capacity, cost savings and reducing operation cost.

. Successfully managed more than 115 capital projects ranging from $4,000

to $12,000,000 in cost.

. Extensive experience of implementing annual cost reduction project

ranging from $40,000 to $8,000,000 "Scrap rate cut 50%. Turnover rate of

12% per month brought to 3% per month. Increase output by twofold.

Profits raised 100% in 1 year. Reaching 1 million man hours without a

lost time injury. Reduce safety injuries cost of 0.75 million to 20K

annually. Reduce equipment down time rate of 60% per month to 7% per

month".

. Extensive use of Quality Control System tools; Statistical Process

Control, First Article (FA) to improve process and reduce cost.

Management of all equipment, site, and facility maintenance and utilities

and manage plant-wide maintenance and capital program, maximizing asset

reliability, uptime, and cost effectiveness with available resources.

Provides long-range planning for the facility and equipment needs

including capital and major repairs, and develop, implement and oversee

predictive, preventative and corrective maintenance programs.

. Knowledge & hand-on experience with Weld Engineering implementation

"robotic/manual", AWS code, GMAW, Robotics programming "Robot studio",

welding techniques, driving process improvement, and facilitating

training in a team environment.

. Carryout manufacturing and weld projects using engineering principles,

developing new methods and process, robotic tooling and fixturing design

as well as advancement of robotics and production automation designs

focusing on quality and cost reduction.

. Expertise and support of weld operations (plant layout, continuous

improvement, capital equipment justification, training, and floor

technical support).

. Carry-out and coordinates prototype production implementation with

attention to team involvement throughout product development using Design-

for-Manufacturing & Assembly (DFM/A) focusing on cost and quality.

. Development of new and existing processes and manufacturing systems to

improve quality, productivity, and reduce operating costs. Development of

new methods and techniques of welding through vendor collaboration,

testing, and exchanges of ideas.

. Evaluation, standardization and writing of welding procedures and

specifications, evaluating weld defects and developing corrective actions

(analysis of weld joints using inspection and testing activities to

validate conformance of weld procedures to industry code and internal

quality conformance procedures).

. Experience in Project management "schedule/agenda development, monitoring

and following-up, maintain budgets for new equipment installations and

new product development introduction. Develop annual and five-year

budgeting and planning requirements for overall facility.

Programming: CNC Machining, robotics (welding "Robot studio", assembly,

fabrication, injection molding, paint, & material handling), Pascal,

COBOL, FORTRAN, laser cutting, & fiber glass winding machines.

Computer literate; PC & Engineering Design Software (Solid Modeling;

IDS/SDR, AutoCAD, Unigraphics, Solidworks & Cad Key; Finite Elements and

Stress/Strain Analysis) programs. Fluent in English & Arabic Languages!

EDUCATION

1994-Bachelor of Science, Industrial Engineering (ABET accredited) minor:

Mathematics

Emphasis: Manufacturing Engineering (manufacturing & management),

laboratory intensive (production process)

University of Minnesota

CERTIFICATIONS

OSHA/EPA Auditor, Lean Manufacturing & Demand Flow Technology (DFT)

training, Design for Manufacturing & Assembly (DFM/A), ISO 9001:2000

Auditor, Total Quality Management System (TQM) training.

PROFESSIONAL EXPERIENCE

Trinity Industries - $2.2 billion (Inland Barge Group) - Port Allen, LA

MFG. of Inland Barges (the largest manufacturer of inland barges and

fiberglass covers for barges in the United States $422 million in sales &

operating profit of $69 millions in 2010.

Plant Manager (320 employees) - March 2010 - March 2011

Responsible for all manufacturing operations, support & administrative

functions needed to blast, paint, steel fabrication, assembly (welding &

fitting)then manufacture/build Inland Huber Barges (200' X 35' X 14').

Directly supervise Safety, HR, Accounting, Purchasing, Lean "continuous

improvement", Quality Control, Maintenance, Operations, Welding, Industrial

Engineering, Materials and Production Control Managers. Supervises

managers, foreman and office personnel; performs under the administrative

direction of division president/general manager and other division leaders.

. Manages subordinate managers; holds subordinates accountable for budgets,

schedules, performance standards.

. Determines organizational structures with top management approval.

. Translate company strategies into tactical plans.

. Creates and prioritizes necessary resources and steps required to

accomplish goals on time.

. Establishes/Coordinates with all functional areas of the plant to ensure

production schedules are met.

. Confers with Business Unit Department Heads to ensure coordination of

purchasing, production and shipping.

. Develops departmental plans, including business, production and/or

organizational priorities.

. Prepares annual budgets, projections, quarterly reports, including

capital budgets.

. Advises departments regarding manning and expense goals and ensures

efforts are made to meet budget projections.

. Determines plant improvements and repairs along with annual costs and

schedules.

. Utilizes Continuous Improvement Strategies & provide technical leadership

for overall plant operations.

Bush Hog LLC - Selma, AL & Telford, TN

MFG. of agricultural equipment (rotary cutters & mowers, loaders &

backhoes, turf & landscape equipment, off road utility vehicles $160

million in sales.

Manufacturing Engineering Manager/Operation Lead - June 2008 - December

2009

Directed the manufacturing engineering (8 reports), short run/kitting

production (15 reports), and fabrication, welding manufacturing operations

(60 reports) of rotary cutters, mowers and other agricultural equipment

with annual net sales over $160 million and an operating budget of $37.3

million.

> Member of Leadership/Management Turnaround Team; $100 million loss in

the last 5 years ($32 million loss in 2008) to a profit of nearly $5

million in the first 6 month of 2009.

> Team champion to consolidate two manufacturing facilities into one;

Bush Hog Selfield & Bush Hog Selma, AL. Projected annual savings are

estimated to be in the range of $6.9 to 7.4 millions beginning in

2009.

. Provide technical leadership for overall plant operations.

. Collaborate with plant staff to achieve high levels of customer service,

product quality, and manufacturing efficiency.

. Develop and sustain robust manufacturing processes and equipment.

. Lead cost reduction initiatives and sustaining manufacturing engineering

requirements on existing product lines.

. Conceive, justify, and implement significant cost reduction projects.

Terex Corporation - Terex Utilities, Huron, SD

MFG. of heavy equipment, cranes, digger derricks and aerial lifts $6.7

billion in sales.

Plant Manager - January 2007 - May 2008

Directed the manufacturing operations of truck mounted digger derricks and

aerial lifts major components (cylinders, jack legs, sub frames, pedestals,

turntables and booms) with annual net sales over $180 million and an

operating budget of $3.2 million. Manage a staff of 198 employees through

nine supervisors and four Quality/Manufacturing Engineers.

. Increased on-time shipments to customers to from 56% to 90%.

. Reduced direct labor by 11% and reduced required floor space by 10%

primarily through Kaizen events and workshops teams.

. Increased plant-wide productivity 13% in past five months by identifying

and eliminating process waste.

. Provide leadership to successfully fast track the implementation of Lean

Manufacturing.

. Direct, lead and coordinate manufacturing activities in compliance with

required output and Quality standards.

. Participate in the overall strategic planning, design and direction of

manufacturing processes and specifications.

. Oversee the training of employees, setting of departmental production and

performance goals, safety and organization of work, along with

maintenance of a productive and motivational climate.

Alamo Group, Gibson City, IL

MFG. of mounted mowing, street sweepers, excavators with over $365 M in

sales.

Manager, Manufacturing Engineering/Production & Maintenance - January 2006

- December 2006

Directed the manufacturing engineering and production (fabrication &

welding) operations of mounted mowers and other agricultural equipment with

annual net sales over $60 million and an operating budget of $4.3 million.

. Facilitated team to consolidate two manufacturing facilities into one;

Alamo Group IL and Alamo Group KS; Projected annual savings are estimated

to be in the range of $2.7 to 3.0 millions beginning in 2007.

. Managed production staff of over 80 employees through three supervisors &

four manufacturing engineers.

. Reduced required floor space by 18% primarily through 5S's, Kaizen

workshops and problem solving teams.

. Increased plant-wide productivity by 10% in 2006 fiscal year by

identifying and eliminating process waste.

. Participated on management teams that defined business requirements and

facilitated change management system implementation.

Gehl Company, Madison, SD

MFG. of agriculture and compact construction equipment with over $300M in

sales.

Sr. Manufacturing Engineer (Fabrication, Welding, Paint & Assembly) -

January 1999 - December 2005

Managed the manufacturing engineering operations of six seating product

lines, including three Skid Loaders design projects, 1-new product and 2-

product updates "2000-2005"

Managed a staff of 18 employees (3 ME's, 10 maintenances techs, 3

toolmakers, one supervisor).

Fully responsible for Gehl's $11.8 & 4.8 million South Dakota skid loader

expansion project (2000 & 2002).

Successfully completed capital justification, purchase, programming (on/off

line" using Robot Studio") and the implementation of 16 ABB robotic

welding technology cells ($2.8 million), 1999-2000.

Managed the manufacturing engineering operations of six-seating product

lines, including three Skid Loaders design projects updates "2000-2005"

Prepared and delivered 50,000 sq. ft. facility expansion layout coupled

with a remodeling project of 20,000 sq. ft. in the existing plant, 2000.

Prepared and delivered 80,000 sq. ft. facility expansion layout in the

existing plant to merge Gehl-Mustang plants and CEA Attachments Inc.,

2002.

Complete purchase and implementation of new state of the art paint system

and productivity enhancing equipment (ex. 2-FMS lasers &

horizontal/vertical machining centers) 2000-2005.

Reengineered plant/facility layout for welding, fabrication, machining

shop, and assembly improving product flow by 80% and increased out put by

50%.

Implemented robotic welding utilization project to six-products with annual

cost reduction of $727,000, 2003-2004.

Reviewing and interpreting customer specifications, and product

requirements. Determining engineering calculations and projected pricing.

Developing engineering designs and sizing project requirements using

project management tools and techniques, Design for Manufacturing and

Assembly (DFM/A). Interfacing with design engineering and production on

special design requirements, and oversee prototype and product launches.

Overseeing the implementation of Lean Manufacturing (Value Stream Mapping,

Quality at the Source, Mistake Proof, kaizen continuous Improvement, 5S

Workplace Organization, Total Productive Maintenance, Visual Management,

Setup Reduction, One Piece- Flow, Cellular Manufacturing, Standardized

Work Instruction, Processes Balancing, Production Leveling/Smoothing,

Point-of-Use System, and Kanban), and Demand Flow Technology (DFT)

concepts through out the facility, 2000-2005.

Trained team members on corrective action process, focusing on root cause

analysis.

Initiated quality auditing program and SPC reviews at key suppliers.

Floor support and hands-on activities including training & problem solving.

Terex-Utility (Telelect), Watertown, SD

MFG. of heavy construction equipment, digger derricks and aerial lifts.

Manufacturing Engineer/Safety Director - January 1997 - December 1998

Administration & management of all facets of health and safety.

Establishing safety & health program standards.

Serve as the corporate contact for OSHA, EPA, & local compliance officers.

Fully responsible & accountable for ensuring continuous improvement in

processes, quality, and cost.

Identify and develop improved methods and processes for the manufacture and

assembly of the product.

Manage engineering design changes implementation to include definition of

solution, expedition of change, participation in material review group

and facilitation of implementation.

1. Directing and supporting the manufacturing engineering team in the

development and/or improvement of manufacturing processes involving

fiberglass boom winding, curing, hand lay up, spray up, gel coating,

finishing and bonding of composite products in support of the aerial

lifts boom trucks business.

UMI, Spantek Div., Hopkins, MN

Manufacturer of blank-to-size expanded metal.

Plant Supervisor/Manufacturing Engineer & Engineering Internship - May 1993

- December 1996

Managed manufacturing operations (over 80 employees through 3 production

supervisors) insuring continuous processes improvement, quality, safety,

cost and service.

Direct/indirect labor saving 17%, annual factory cost savings 20%.

Reduced lead-time from 4-6 weeks to 1-2 weeks and customer rejection

reduced 71%.

Medical incidents reduction of 57% and annual worker's compensation reduced

65%.

Establishing employees training requirements and developing a cross-trained

multi-functional workforce.

Designed process to eliminate industrial oil lubricant waste used in the

process of expanded metal.

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