Carl Smith
Graniteville,SC
Summary
A results oriented professional, with strong qualifications in strategic planning, manufacturing, production scheduling and control, inventory/materials management, project management, budgeting, human resources management, and time critical situations; cultivation of efficient and effective working teams; self-motivated, honest and dependable, with excellent communication skills, and solid contributions toward driving organizational change and improvements.
Overview
17
17
years of professional experience
Work History
Senior Production Manager
Bridgestone Americas
05.2017 - Current
- Direct 15 Salary employees and approximately 460 hourly production teammates
- Monitor safe work practices and align with Line-Driven Safety processes, promote a positive safety trend; plant received OSHA VPP Certification; meet environmental standards and specifications
- Developed and implemented a quality tracking system to evaluate and utilize data by shift, department, category (daily, weekly, monthly), improving scrap by 8.9%, with an overall savings of $612K
- Develop and execute production schedules, based on business demands; plan workflow, manage multiple priorities and meet daily production targets
- Analyze and assist in the preparation of yearly and five-year budget plans, to ensure operating plans are strategically aligned; monitor budget execution monthly, to ensure organizational requirements are in line with yearly spend plan
- Returned $1.2 million in operational costs to the plant by setting goals through continuous improvement activities with leaders and cross-functional teams
- Leveraged partnerships with HR to reduce turnover rates by 13%
- Empower team members to maintain an absenteeism rate of 3% lower than the department previous year
- Developed and implemented job certifications and testing to build multi-skilled cross functional teammates; created rotation and training plan to improve job performance and production efficiencies
- Plan and directed the start-up of manufacturing equipment in multiple departments and processes to ensure meeting customer demands
- Assist Operations/Plant Manager in strategically planning 1, 5, and 10-year vision for future business, constraints and departmental bottleneck challenges
- Assisted direct reports in developing and implementing department scorecards to track key performance metrics
- Implemented a system to track overtime on a weekly basis for the department; system allows supervisors and managers to review, track and manage overtime (by teammate, department and codes being charged), to maintain and reduce overall plant cost.
Kaizen (Continuous Improvement) Leader
Bridgestone Americas
08.2007 - 05.2017
- Promote safety awareness, initiate and monitor safety programs for training and inspections at the department level
- Investigate and countermeasure safety incidents for root cause analysis while developing plans for improvements
- Direct tire assembly manufacturing operations that support producing 32,000 tires daily
- Directly manage nine salary employees and 180 non-exempt team members
- Manage a departmental annual operating budget of 25 million dollars
- Focusing on people and non-people cost
- Monitor, coordinate and implement countermeasures for quality control systems to ensure standards are updated and current
- Ensure forward plans are in place for continuous improvement projects and strategic planning initiatives
- Establish plan and control points for production requirements, communicate objectives to team members, interact and coordinate activities with support groups
- Direct resources within and outside the department to improve and correct deficiencies, initiate countermeasures, report and monitor results
- Direct and control all departmental cost activities consistent with policy, budget, waste, scrap, and repair objectives
- Monitor and analyze department performances, countermeasure adverse trends of problem areas for expected results, obtain and deploy resources as necessary and establish effective cost reduction program
- Conduct all kaizen meetings and events which resulted in production profit improvement savings based on improved productivity, improved quality and in waste reduction
- Utilize 6 Sigma to achieve a 44% reduction in cycle stop alarms resulting in an annual profit of $114,912
- Coordinated manpower refinements that save the company $240,000 annually.
Education
Lean Six Sigma Black Belt -
University of South Carolina
Columbia, SC2021
Master’s degree - Business Management
University of Phoenix
Phoenix, Arizona2009
Bachelor’s degree - Business/Management
University of Phoenix
Phoenix, Arizona2005
Associate degree - Technology, Maintenance
Aiken Technical College
Aiken, South Carolina1999
Diploma - Electrical Construction & Maintenance
Augusta Technical College
Augusta, GA1993
Skills
- Material Planning
- Operational Efficiency
- Health and safety compliance
- Workflow Optimization
- Team Development
- Continuous improvements
- Strategic Planning
- Project Management
Interests
Affiliations
, Aiken, South Carolina Vocational Rehabilitation - Advisory Board Member
South Carolina Manufacturers Alliance - SC Automotive Council Board
Additional Information
- LICENSES, Certifications & Awards , South Carolina Electrical Contractor License, 2009 Green Belt Six Sigma Certification, 2007
Timeline
Senior Production Manager
Bridgestone Americas
05.2017 - Current
Kaizen (Continuous Improvement) Leader
Bridgestone Americas
08.2007 - 05.2017
Lean Six Sigma Black Belt -
University of South Carolina
Master’s degree - Business Management
University of Phoenix
Bachelor’s degree - Business/Management
University of Phoenix
Associate degree - Technology, Maintenance
Aiken Technical College
Diploma - Electrical Construction & Maintenance
Augusta Technical College
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