Summary
Overview
Work History
Education
Skills
Accomplishments
Affiliations
Certification
Languages
Timeline
Generic

David Barnes

El Paso,TX

Summary


Results-driven management professional with proven track record in overseeing plant operations and optimizing production processes. Adept at fostering team collaboration and ensuring operational efficiency while adapting to evolving demands. Strong skills in resource management, process improvement, and safety compliance. Reliable and goal-oriented, consistently delivering impactful outcomes through strategic leadership and decisive action.

Overview

42
42
years of professional experience
1
1
Certification

Work History

Plant Manager

Design Group
01.2002 - Current
  • Directed production operations, ensuring adherence to safety protocols and efficiency standards.
  • Oversaw maintenance schedules, maximizing equipment uptime and minimizing downtime.
  • Implemented process improvements, enhancing productivity and optimizing resource allocation through shop floor continuous improvement.
  • Led cross-functional teams to achieve operational goals and foster collaborative work environments.
  • Customer focused with strong involvement with planning, execution, quality, and on time delivery
  • Employee focused with Leadership training to provide excellent work environment demanding respect at al levels.
  • Implemented process improvements, enhancing productivity and optimizing resource allocation.
  • Relocated operations from Hagerstown, MD to CD Juarez, Chihuahua, MX. Expanded multiple times culminating in 2nd factory start up in 2023.
  • Developed training programs for staff, promoting skill advancement and operational excellence.
  • Coordinated supply chain activities, ensuring timely delivery of materials and reducing lead times.
  • Managed budget forecasting and cost control initiatives, driving financial performance within plant operations.
  • Increased production efficiency by optimizing plant layout and implementing process improvements.
  • Reduced costs by eliminating materials waste and unnecessary labor hours.
  • Directed employees and related programs to maximize team productivity and facility output.
  • Provided direction and leadership to all levels of employees and managers.
  • Boosted employee morale and productivity through effective leadership and motivational techniques.
  • Monitored and evaluated plant performance to identify areas for improvement and take corrective measures.
  • Led, trained and coached plant staff to facilitate high levels of productivity and quality.
  • Balanced labor needs with production schedules to optimize workforce utilization while maintaining output targets.
  • Maximized plant safety through proactive strategies and well-structured training.
  • Created plant policies and procedures for safe and productive operations.
  • Forecasted future production needs accurately, allowing for strategic decision-making regarding staffing levels, equipment investments, and inventory management.
  • Mentored and developed staff members, promoting professional growth opportunities within the organization.
  • Managed direction and planning for plant with focus on optimization of daily functions, exceeding customer expectations, and achieving KPIs.
  • Identified and resolved process and equipment issues to minimize production downtime.
  • Promoted collaborative work environment to motivate and engage staff to achieve company objectives.
  • Built strong relationships with regulatory agencies and ensured compliance with all environmental permits; maintained an exemplary safety record.
  • Established positive relationships with suppliers to obtain timely deliveries of materials and products.
  • Coordinated plant expansions and upgrades to accommodate increased demand while minimizing disruption to ongoing operations.
  • Developed cross-functional teams to foster collaboration and improve communication across departments.

Plant Manager

Design Group
01.1999 - 01.2002

Relocated operations from Danville, VA to Hagerstown, MD.

  • Developed training programs for staff, promoting skill advancement and operational excellence.
  • Analyzed production data to identify trends, informing strategic decision-making for process enhancements.
  • Coordinated supply chain activities, ensuring timely delivery of materials and reducing lead times.
  • Implemented process improvements, enhancing productivity and optimizing resource allocation.

Plant Manager

Design Group
10.1994 - 01.1999
  • Managed budget forecasting and cost control initiatives, driving financial performance within plant operations.
  • Increased production efficiency by optimizing plant layout and implementing process improvements.
  • Reduced costs by eliminating materials waste and unnecessary labor hours.
  • Directed employees and related programs to maximize team productivity and facility output.
  • Provided direction and leadership to all levels of employees and managers.
  • Boosted employee morale and productivity through effective leadership and motivational techniques.
  • Monitored and evaluated plant performance to identify areas for improvement and take corrective measures.
  • Led, trained and coached plant staff to facilitate high levels of productivity and quality.
  • Balanced labor needs with production schedules to optimize workforce utilization while maintaining output targets.
  • Maximized plant safety through proactive strategies and well-structured training.
  • Created plant policies and procedures for safe and productive operations.
  • Forecasted future production needs accurately, allowing for strategic decision-making regarding staffing levels, equipment investments, and inventory management.
  • Mentored and developed staff members, promoting professional growth opportunities within the organization.
  • Managed direction and planning for plant with focus on optimization of daily functions, exceeding customer expectations, and achieving KPIs.
  • Collaborated with sales team to align plant capabilities with customer demands, fostering long-term business relationships.
  • Implemented quality control measures to reduce defect rates and enhance product quality consistently.
  • Implemented useful inventory management and tracking systems to reduce costs and improve operations.
  • Conducted thorough root cause analyses on production issues, identifying solutions for continuous improvement efforts.
  • Promoted collaborative work environment to motivate and engage staff to achieve company objectives.

Fabrication Supervisor, IE, Planning Manager

Armstrong World Industries
06.1983 - 09.1994
  • Led cross-functional teams to enhance operational efficiency and drive strategic initiatives.
  • Developed and implemented performance metrics to measure team effectiveness and productivity.
  • Mentored junior managers, fostering professional growth and ensuring best practices in management.
  • Streamlined processes by identifying bottlenecks and implementing innovative solutions for improved workflow.
  • Conducted regular performance reviews, providing feedback to enhance team capabilities and morale.
  • Managed budgetary allocations, ensuring resource optimization across multiple projects and departments.
  • Managed and motivated employees to be productive and engaged in work.
  • Accomplished multiple tasks within established timeframes.
  • Maintained professional, organized, and safe environment for employees and patrons.
  • Resolved staff member conflicts, actively listening to concerns and finding appropriate middle ground.
  • Maximized performance by monitoring daily activities and mentoring team members.
  • Controlled costs to keep business operating within budget and increase profits.
  • Achieved departmental goals by developing and executing strategic plans and performance metrics.
  • Reduced operational costs through comprehensive process improvement initiatives and resource management.
  • Streamlined project delivery processes, significantly reducing time to market for new product launches.
  • Facilitated team brainstorming sessions that led to innovative solutions for long-standing operational challenges.
  • Organized professional development programs for staff, leading to improved performance and skill sets.

Education

Bachelor of Science - Industrial Engineering And Operations Research

Virginia Tech
Blacksburg
06-1982

Skills

  • Plant and warehouse operations
  • Project management
  • Operations management
  • Production planning
  • Continuous improvement
  • Performance improvements
  • Facility management
  • Safety management
  • Team building and development
  • Lean manufacturing processes
  • Cost controls
  • Waste reduction
  • Project coordination
  • Compliance

Accomplishments

  • Supervising team of 25 staff members.
  • Manage 2 facilities of 500 employees
  • Achieved $1.1M savings in 1st year of operation vs goal of $700K.
  • Reduce quality incident rate by 50%.
  • Reduced waste by $500K over 5 years
  • Increased operational up time by 25% through shop floor continuous improvement technique.
  • Improved customer fill rates to 98% level.
  • Excellent NOM 35 performance due to leadership development programs and expectations

Affiliations

  • SouthWest Maquila Association
  • INDEX Maquila Association

Certification

Certified Manager

Languages

English
Full Professional
Spanish
Limited Working

Timeline

Plant Manager

Design Group
01.2002 - Current

Plant Manager

Design Group
01.1999 - 01.2002

Plant Manager

Design Group
10.1994 - 01.1999

Fabrication Supervisor, IE, Planning Manager

Armstrong World Industries
06.1983 - 09.1994

Bachelor of Science - Industrial Engineering And Operations Research

Virginia Tech