Douglas Shank
Elkhart,IN
Summary
Dedicated Plant Operations Manager bringing demonstrated record of success and 20+ years of experience in Automotive manufacturing environments and traffic safety equipment. Focused on controlling costs, eliminating overages and enhancing efficiency using hands-on approach. Inspires and influences teams to build cohesion, enhance knowledge and increase productivity, safety and quality.
Overview
25
25
years of professional experience
Work History
General Manager
Scientific Developments Inc.
Elkhart, IN
10.2021 - 05.2024
- Managed 40 million dollars in sales over 2 plants, Elkhart, IN and Eugene, OR
- Labor efficiency increase of 100% due to daily cycles on machines from 25 to 52
- Reduced work force by 50% for a cost savings of 1.8 million dollars
- Implemented a quality control process
- Process improvements using design and development for an annual cost saving of $500,000+
- Direct reports including Plant Managers, Material Managers, Maintenance and Shipping/Receiving
- Maker of Rubber and Plastic Traffic Safety Equipment
Plant Manager
Wayne Manufacturing
Laotto, IN
08.2015 - 10.2021
- Managed $28 million in sales with a profit margin of 18%.
- Direct labor efficiency of 98%
- Scrap less than one half percent
- Direct reports include Maintenance Manager, Production Manager, Materials Manager and Quality Manager; total work force of 70 employees.
- Completed a total 5S restoration of entire plant.
- 2 complete robotic assembly cells and 6 robotic CNC machining centers with a labor savings of $550,000.
- Focused on safety, 1 lost time accident in 5 years.
- IATF 16949 certified.
- Producing Automotive Metal Stampings
Operations Manager
Cooper Standard Automotives
Auburn, IN
11.2011 - 08.2015
- Managed $2.7 million variable cost budget to goal, for a $150 million plant sales.
- Directed 8 supervisors, master scheduler, and 200 hourly associates for assembly, paint, warehousing and molding.
- Direct labor efficiency gain from 78% to 92% by using the team concept approach and lean principals.
- Scrap at less than 1% by the use of a cross functional team to evaluate scrap.
- Lean savings of $600,000 in two lean events.
- Launched three successful Ford programs with 0 accidents, 0 quality defects, 100% on time delivery for the first 30 days.
- Team has had 0 lost time injuries for the past three years.
- Negotiated a two tier wage system driving down labor cost.
- Producer of rubber injection molding.
Production Manager
Bosch Rexroth
Buchanan, MI
06.2008 - 11.2011
- Managed $1 million variable cost budget to goal for $40 million plant.
- Directed 3 lead operators, master scheduler and 27 hourly associates for assembly, machining, warehousing, maintenance and shipping.
- Reduced down time 25% by establishing visual production management board.
- Increased efficiency 30% using lean design to set work areas in one-piece flow.
- Eliminate 75% of the mobile equipment by developing milk run, using Kaizen techniques.
- Achieved no lost time or recordable injuries for 2 years as plant safety advocate.
- Producer of aluminum conveyance systems.
Project Manager/Materials Manager
Alcoa Inc. Auto Truck Structures
Auburn, IN
12.2005 - 04.2008
- Directed 2 managers, 6 supervisors, master scheduler, logistics supervisor, 14 lead operators, die shop and 160 hourly associates for assembly, machining, maintenance, and shipping.
- Managed $15 million budget including labor and material, for $80 million plant.
- Reduced WIP and inventory costs by implementing plant-wide visual Kan Ban to level load scheduling, production, establish production goals and set audible "pace".
- Achieved TS 16949 certification by implementing and documenting quality and manufacturing processes.
- Achieved 0 lost time as safety team leader responsible for environmental, health and safety.
- Producer of aluminum extrusions.
Manufacturing Manager
Faurecia Exhaust Systems
Granger, IN
08.2003 - 09.2005
- Established team leader concept plant wide.
- Implemented Toyota Production System plant wide.
- Constructed the model line for the plant.
- Reduced overtime by 25% by using takt time and setting he pace for the plant.
- Responsible for a three shift operation including 8 supervisors, 250 hourly associates, assembly, engineering, setup, quality, and maintenance with an overall plant efficiency of 82%.
- Cost savings for the first year of $750,00.
- QS 9000 and ISO 14001 certified.
- Producer of automotive exhaust systems.
Manufacturing Manager
Meridian Automotive Systems
Grabill, IN
04.1999 - 07.2003
Rexroth
- Instituted plant wide Toyota Production System; reduced overtime 50% by using takt time to set "pace" in 33% of the predicted time.
- Saved $2.5 million, first year, and reduced labor 33% using Kaizen techniques.
- Directed 3 supervisors, 18 team leaders and 200 hourly associates in 3 shift operation including molding, assembly, prime, and top coat.
- Improved quality, no rejects for 2 years, by using mistake proofing techniques.
- Successful on time start up and launch for Ford Lincoln Navigator program.
- Achieved QS 9000 and ISO 14001 certification as part of 8 person team.
- Saved an average of $800,000 in each of 13 plants as internal lean consultant as taught by Yomo Consulting Group.
- Producer of automotive fiberglass and metal body parts.
Education
Bachelor of Science - Business Administration
Indiana Wesleyan University
Marion, INAssociate of Applied Science - Welding And Metallurgical
Olney Central College
Olney, ILTimeline
General Manager
Scientific Developments Inc.
10.2021 - 05.2024
Plant Manager
Wayne Manufacturing
08.2015 - 10.2021
Operations Manager
Cooper Standard Automotives
11.2011 - 08.2015
Production Manager
Bosch Rexroth
06.2008 - 11.2011
Project Manager/Materials Manager
Alcoa Inc. Auto Truck Structures
12.2005 - 04.2008
Manufacturing Manager
Faurecia Exhaust Systems
08.2003 - 09.2005
Manufacturing Manager
Meridian Automotive Systems
04.1999 - 07.2003
Bachelor of Science - Business Administration
Indiana Wesleyan University
Associate of Applied Science - Welding And Metallurgical
Olney Central College
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