Brian T. Bahrs
Rock Falls,IL
Summary
Senior Maintenance Leader with over 39 years of Maintenance Experience. Served as a Corporate Maintenance Manager for 16 plants for Morgan Truck body, Operations Manager & Maintenance Lead for Cummins Inc. Certified Lean Six Sigma Black Belt since 2013, Spent 5 years working as a Manufacturing consultant, specializing in maintenance processes, Strategy Planning.
Overview
24
24
years of professional experience
Work History
Maintenance Contract Consulting
Oxford Globel Resources
02.2024 - 07.2024
- Responsible for the training of personnel to use CMMS system properly and efficiently
- Reason for leaving – Contract is coming close to ending
- Developed customized preventive maintenance programs tailored to the specific needs of each client's facilities.
Maintenance Contract Consulting
Mindlance
Davenport, IA
11.2023 - 02.2024
- Responsible for the supervision of the 2nd shift maintenance team of 14, PM completion, work scheduling and prioritization
- Reason for leaving – Contract has ended
Maintenance Manager (Consultant)
Cusano’s Bakery LLC
11.2022 - 06.2023
- Direct all reliability & maintenance activities of 14 reports, 2 supervisors, 1 MRO purchaser and 11 technicians
- CAPEX - Managed the installation and layout of a $40m new equipment purchased Assessed the EHS of the line to include PM procedures for the equipment and food safety, tasks, frequencies, critical spares, and have them implemented into a computer maintenance management system
- Introduce a mobile application to collect data from reactive equipment failures for root cause analysis
- Implemented a predictive maintenance program
- Monitored priorities and liaised between maintenance team and management, delegating tasks to complete on time.
- Established and documented protocols for preventive maintenance procedures, decreasing equipment issues, and reducing downtime.
- Delegated tasks to carefully selected employees in alignment with resource management goals.
- Supervised employee performance, preventive maintenance, and safety.
- Managed a team of technicians, providing guidance and support for skill development and performance improvement.
- Reason for leaving – Contract has ended
Maintenance Manager
Tree House Foods LLC
07.2021 - 11.2022
- Direct all reliability & maintenance activities of 17 reports, 1 supervisor, 1 planner, 1 procurement and 14 technicians
- Responsibilities include all functions in the areas of Maintenance Business Management, Maintenance Materials Inventory (MRO), Manufacturing Process Reliability & Equipment Reliability
- Accountable for the computerized maintenance management system (SAP)
- Development, coordination & execution of maintenance related CAPEX budget of $2m, items in concert with engineering
- Identified KPI’s (criteria) to prioritize work for the preventive/predictive and corrective maintenance work orders
- Increased OEE from 36% to over 71% in less than 8 months by conducting Kazan events with the SME of the equipment and/or production lines with poor performance
- Reason for leaving – My home burnt down to the ground, and I need more time off to take care of the matter than they were willing to provide
Maintenance Contract Consulting
Oxford Global Recourses
04.2017 - 07.2021
- Audited Computerized Maintenance Management System’s (SAP, Maintimizer, Maintenance Connection and COGZ to name a few) to ensure that they optimize the use of valuable resources (manpower, equipment, material, & funds) to maintain facilities & equipment
- Assess workflow processes at facilities identified the gaps then implement changes to these processes to give local management control over the reliability of all maintainable equipment from acquisition to decommission & disposal
- Addressing all resources involved
- Changed the cultures of maintenance teams to partner with production and quality teams to ensure effective management of equipment downtime and speedily resolutions of any issues
- Supporting product, process & equipment analysis & improvement projects
- Lead teams to resolve open issues, drive process improvements in design, layout & operational performance
- Provide technical expertise and leadership in troubleshooting failures and help identifying the root cause
- Established good working relationships with the plants and local vendors to ensure materials, supplies and third-party repairs are delivered at the best possible cost
- Developed a leadership playbook which consisted of daily and weekly routines with instructions on how to use their ERP, and CMMs systems to help track assets and team performance and prioritize work that will best affect the business
- Assessed new equipment purchased for PM procedures, tasks, frequencies, critical spares, and have them implemented and spares purchased prior to installation to ensure once installed the facilities were ready to maintain
- Developed baseline Warrantee Tracking, Changeover Tracking, and Spare part repair tracking processes for a multi-site manufacture
- Tailoring each process as needed to fit the different organizational structures found at a facility
Maintenance Manager
Kraft Heinz
Muscatine, Iowa
03.2016 - 03.2017
- Direct all reliability & maintenance activities of 53 reports, 3 supervisors, 1 planner, 1 procurement and 48 technicians
- Responsibilities include all functions in the areas of Maintenance Business Management, Maintenance Materials Inventory (MRO), Manufacturing Process Reliability & Equipment Reliability
- Accountable for an annual budget of 8.3M, computerized maintenance management system (CMMS)
- Development, coordination & execution of maintenance related CAPEX & Operating budget of $8m, items in concert with engineering
- Identified KPI’s (criteria) to prioritize work for the preventive/predictive and corrective maintenance work orders
- Conducted Kazan events with the SME of the equipment and/or production lines with poor performance
- Reason for leaving – In a Company restructuring, maintenance was absorbed into production, the maintenance team now operates the equipment and when the machines need maintenance, they are responsible for making the repairs
- My position as Maintenance Manager was eliminated
2nd shift Operations Manager for Machining A&B
Cummins Inc
Whitakers, North Carolina
01.2016 - 03.2016
- Manage, develop, and lead the daily activities of multiple production teams
- Responsible for the daily activities of 465+ indirect reports of multiple production teams to meet production targets
- Worked cross functionally to improve safety, productivity, quality, and efficiency of operations
- Provides guidance and feedback for team members in accomplishing tasks and goals; sets expectations and clarified areas of responsibilities
Maintenance Lead
Cummins Inc
Whitakers, North Carolina
07.2015 - 01.2016
- Reduced maintenance downtime events by 47% which has allowed production to increase its parts per hour by 20%
- A pace that has never been accomplished in the 18 years of existence as a facility
- This was done by changing the culture to a united front of operations and maintenance working together instead of separate units
- Direct leadership of maintenance team of 18 direct reports and other staff
- Developed objectives and standards of performance for projects within the maintenance department required to meet departmental and corporate goals and objectives
- Reason for leaving – I was part of a corporate downsizing of 2000 salary employees
Corporate Maintenance Manager
Morgan Truck Body
Morgantown, Pennsylvania
05.2014 - 07.2015
- Developed objectives & standards of performance for projects within the maintenance department required to meet departmental & corporate goals & objectives of 16 facilities
- Development, coordination & execution of CAPEX projects depending on the size of the 16 plants budgets would range from $1.2m – $3m, items in concert with engineering and individual plants needs
- Identified KPI’s (criteria) to develop work instructions and implemented a preventative maintenance program
- Built a good working relationship with each plant’s local vendors to ensure materials, supplies and third-party repairs are delivered and accomplished to corporate standards
- Coached and mentored team members
- Identified training needs and developed and implemented training plans to close the gaps
Facilities & Maintenance Manager
Great Dane Trailers
Kewanee, Illinois
12.2011 - 05.2014
- Oversaw a 58,000 sq
- Ft
- Expansion CAPEX project of $8m of the warehouse and production line from groundbreaking to turnover
- Which included the filing for the permits, ensuring all building codes are complying and all environmental and safety regulations are being complied with
- Developed a down time tracking and work order process also a preventative maintenance program for the equipment to effectively reduce unscheduled down time
- Lead Kaasen’s and 5S’s events
- Coordinated maintenance tasks between operations, maintenance team and commercial venders to minimize down time
- Conducted weekly maintenance operations meetings to ensure all safety and mechanical issues are addressed in a timely manner
- Manage department financials with a maintenance budget ($1,688,623.00)
- Lead multidisciplinary teams in performing Root Cause Analysis and lead the implementation of corrective actions for customer complaints, quality deficiencies, productivity deficiencies, and areas identified for improvement
- Reason for leaving – I was recruited for a higher-level position with Morgan Truck Body
Electrician
Alcoa
Riverdale, Iowa
07.2011 - 12.2011
- Participated in Kaizen events around the 5S’s and 8 wastes to find new ways to simplify the process while still meeting the required outputs Design of electrical controls and monitoring systems
- Programming and calibration of electrical systems
- Assembly, testing and troubleshooting prototypes from schematic drawings
- Reason for leaving – Left for a management position with Great Dane Trailers
Electrical Technician
Silgan Containers Manufacturing, Inc.
Rochelle, Illinois
01.2001 - 07.2011
- Managed all electrical and equipment controls used in production
- Troubleshooting and repair of automated machinery
- Maintenance, programming, and calibration of electrical systems
- Reason for leaving – Left for a position with Alcoa and a better working schedule so I could finish my degree
Education
Lean Six Sigma Black Belt - Lean Six Sigma Black Belt
PURDUE UNIVERSITY
Lafayette, IN01.2014
Bachelor of Science - Business Administration And Management
Western Illinois University
Macomb, IL01.2010
Skills
- Ka Developed a down time tracking and work order process also a preventative maintenance program for the equipment to effectively reduce unscheduled down time
- Lead Kaizen’s and 5S’s events
- Coordinated maintenance tasks between operations, maintenance team and commercial venders to minimize down time
- Conducted weekly maintenance operations meetings to ensure all safety and mechanical issues are addressed in a timely manner
Timeline
Maintenance Contract Consulting
Oxford Globel Resources
02.2024 - 07.2024
Maintenance Contract Consulting
Mindlance
11.2023 - 02.2024
Maintenance Manager (Consultant)
Cusano’s Bakery LLC
11.2022 - 06.2023
Maintenance Manager
Tree House Foods LLC
07.2021 - 11.2022
Maintenance Contract Consulting
Oxford Global Recourses
04.2017 - 07.2021
Maintenance Manager
Kraft Heinz
03.2016 - 03.2017
2nd shift Operations Manager for Machining A&B
Cummins Inc
01.2016 - 03.2016
Maintenance Lead
Cummins Inc
07.2015 - 01.2016
Corporate Maintenance Manager
Morgan Truck Body
05.2014 - 07.2015
Facilities & Maintenance Manager
Great Dane Trailers
12.2011 - 05.2014
Electrician
Alcoa
07.2011 - 12.2011
Electrical Technician
Silgan Containers Manufacturing, Inc.
01.2001 - 07.2011
Lean Six Sigma Black Belt - Lean Six Sigma Black Belt
PURDUE UNIVERSITY
Bachelor of Science - Business Administration And Management
Western Illinois University
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