Brian Rathsack
Humboldt,TN
Summary
Dynamic Plant Manager with a proven history of driving productivity and fostering growth within manufacturing environments. Expertise in change management, operational enhancements, and cost reduction, with a strong emphasis on safety and compliance. Demonstrated success in staff management and continuous process improvement, consistently achieving performance targets through the application of ISO systems and Lean Six Sigma methodologies. Recognized for a hands-on management style that enhances output and quality while elevating employee satisfaction, supported by a successful 29-year career in manufacturing leadership.
Overview
29
29
years of professional experience
1
1
Certification
Work History
Plant Manager
Printpack
01.2025 - Current
- Managed production operations at two plants with 140 teammates to ensure strict adherence to quality standards and implement safety protocols.
- Refined manufacturing operations, cutting waste and elevating efficiency in several departments.
- Led cross-functional teams to reach operational objectives and foster enhanced workplace collaboration.
- Implemented training programs for staff driving skill development and reinforcing culture of continuous improvement.
- Executed plant turnaround, confirming accurate teammate placement in functions.
Plant Manager
ProAmpac
01.2020 - 07.2024
- Directed the operations of a manufacturing plant housing nearly 200 employees, overseeing all aspects including P&L management for a vast production and warehouse space spanning over 504K square feet.
- Managed a team in optimizing machinery operations, contributing to a revenue increase from $110M to $210M within four years. Increased EBITDA to 23% vs target of 22%.
- Implemented preventive maintenance programs for equipment and machinery. Resulting in a decrease in unplanned downtime by 10% YTD. Target 4%, running at 2.1%.
- Reduced overall inventory, 9M vs a target of 6M, in order to free up cash.
- Took Days on hand inventory from 50 days down to 33 days, against a goal of 39 days.
- Analyzed production data extensively, identifying potential avenues for improvement and implementing strategic measures. Bringing our OTIF from 83% to the current YTD of 98% OTIF vs Target of 95%.
- Implemented CI projects focusing on waste reduction and efficiency, resulting in achieving a cost savings goal of 1.25M by mid-year, expecting an additional 900K of savings above goal.
- Reduced waste from 13% to 10.5%, vs a goal of 12%.
- Achieved world-class quality by having claims of 0.15% of Total Revenue vs a target of 0.20% for three years straight.
- Accomplished additional cost savings of 300K beyond expected savings by successfully implementing a project focused on pallets.
- Fostered an environment of safety, responsibility, and engagement, resulting in one year without any incidents or lost time, vs. a target of 2.0 after reducing TIR level from 3.5.
- Created and enforced performance targets, conducting regular evaluations of team members.
- Managed the full employee life cycle, enhancing team performance through regular evaluations and grievance resolution.
- Developed budgets and approved expenditures for supplies, materials, and human resources, checking that materials, labor, and equipment met and exceeded production targets/goals.
Production Manager
ProAmpac
07.2018 - 01.2020
- Oversaw operations of a team consisting of more than 10 direct reports and over 120 individuals within the production department.
- Provided training to staff on safety procedures, quality standards, and equipment operation.
- Achieved efficient inventory management and excellent customer satisfaction through meticulous record-keeping and operational oversight.
- Innovated problem-solving methodologies to overcome difficulties in daily operations.
- Enhanced team member performance by offering relevant coaching and growth opportunities.
- Optimized production processes, increased capacity for assets, reduced costs, and ensured high-quality output.
- Led and measured daily processes to promote excellent order fulfillment and production.
- Conducted thorough data analysis to identify strategies for optimizing productivity and quality control.
Raw Material Purchasing Manager
NPS Corp.
07.2017 - 07.2018
- Managed purchasing of Raw Materials with an annual spend of $45M.
- Achieved significant cost savings of $850K through successful negotiations with multiple vendors, versus a goal of $200K.
- Implemented system to maintain inventory levels within target while consistently meeting asset service requirements.
Design Team Manager (Production Manager)
Appvion
07.2015 - 06.2017
- Managed multiple day-to-day operations, enhancing productivity and efficiency in a fast-paced setting.
- Led a team of 60 indirect reports and directly supervised 9 employees, ensuring the provision of tailored feedback, coaching, and effective resolution for intricate employee matters.
- Designed and implemented comprehensive standard operating procedures, performed recruiting/training functions, and oversaw safety related programs.
- Delivered a 15% increase in productivity on the organization's main asset, while pinpointing $300 thousand in cost savings.
- Successfully rolled out a pilot TPM, resulting in an average unplanned downtime rate decrease from 4.1% to 2% vs target of 3%.
- Instituted asset optimization strategies that reduced crewing, saving $390K and improving work environment and efficiency.
Production Manager
Bemis Healthcare Packaging New London (Formerly Perfecseal)
01.2013 - 06.2015
- Oversaw the productivity and operations for a production department with over 120 staff members, while managing a team consisting of more than 10 direct reports.
- Conducted comprehensive training sessions for staff, covering safety procedures, quality standards, and equipment operation.
- Ensured accurate stock records through regular inventory monitoring.
- Managed and optimized daily operations, continually surpassing customer expectations.
- Designed and implemented inventive strategies for overcoming complex obstacles.
- Coached and motivated team members through the provision of suitable training and growth opportunities.
- Enhanced production capabilities, minimized costs, and ensured adherence to quality standards.
- Managed and evaluated daily procedures to optimize order completion and productivity.
- Drove improvements in productivity and quality control through data analysis.
Production Manager/Interim Plant Manager
Perfecseal New London
01.2013 - 07.2013
- Managed all production logistics by leading departmental teams, training individuals in SAP, and monitoring quality levels.
- Put on team to implement and train individuals on SAP. Deployed at six different sites.
- Developed comprehensive policies and procedures while maintaining adherence to ISO compliance regulations.
- Assumed leadership in mitigating emergencies while also handling payroll administration and vacation management duties.
Production Supervisor
Perfecseal New London
03.1997 - 01.2013
- Curwood - Mar. 1997 - Dec. 2002
- Advanced from floor positions to Production Supervisor, overseeing Blown Film lines and serving as a Trainer Relief Supervisor in a union environment.
- Perfecseal - Jan. 2003 - Dec. 2012
- Played a key role in establishing a green field site as the third person on-site, overseeing program development for production and safety.
- Managed production logistics, led departmental teams, trained individuals in SAP and monitored quality levels.
- Created comprehensive policies and procedures, maintaining ISO compliance regulations, and overseeing production schedules for timely completion.
- Took on a leadership role to handle emergency situations while also managing administrative tasks like payroll administration and vacation management.
Education
Master of Arts - Business Analytics
Southern New Hampshire University
Hooksett, NH05-2027
Bachelor Of Science In Business Management - Human Resource Management
Silver Lake College
Manitowoc, WICompleted Coursework Towards Hazardous Waste Material Management -
Lakeshore Technical College
Cleveland, WISkills
- Change agent / Seasoned in Plant Turnarounds
- Lean Six Sigma
- P&L Management
- HR Management / People Development
- Operations Management
- Continuous Improvement
- Safety Program Development
- Green Field Startup
- ISO Compliance / SAP Expertise
- Waste Reduction/Management
- Human Resources
- Project Coordination
Websites
Certification
Lean Six Sigma - Green Belt
Military
United States Army Nation Guard - Mechanic (1993-2001)
Timeline
Plant Manager
Printpack
01.2025 - Current
Plant Manager
ProAmpac
01.2020 - 07.2024
Production Manager
ProAmpac
07.2018 - 01.2020
Raw Material Purchasing Manager
NPS Corp.
07.2017 - 07.2018
Design Team Manager (Production Manager)
Appvion
07.2015 - 06.2017
Production Manager
Bemis Healthcare Packaging New London (Formerly Perfecseal)
01.2013 - 06.2015
Production Manager/Interim Plant Manager
Perfecseal New London
01.2013 - 07.2013
Production Supervisor
Perfecseal New London
03.1997 - 01.2013
Master of Arts - Business Analytics
Southern New Hampshire University
Bachelor Of Science In Business Management - Human Resource Management
Silver Lake College
Completed Coursework Towards Hazardous Waste Material Management -
Lakeshore Technical College