Summary
Overview
Work History
Education
Skills
Certification
Languages
Timeline
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David Michael Welsh

David Michael Welsh

Associate Director of Manufacturing
Grain Valley,MO

Summary

Results-driven manufacturing leader with over 15 years of experience in high-volume FMCG environments, both unionized and non-unionized. Demonstrated ability to achieve cost savings and enhance operational KPIs through effective leadership of cross-functional teams. Skilled in aligning plant operations with strategic business objectives while fostering a culture of safety, quality, and performance.

Overview

18
18
years of professional experience
1
1
Certificate

Work History

Associate Director of Manufacturing

Unilever
Independence, MO
09.2022 - Current
  • Lead the site across multiple functions responsible for Process and Packing Operations, Maintenance/Facilities Maintenance, and Factory Logistics, with up to 295 hourly and 20 salaried direct and indirect reports.
  • Facilitated cross-functional collaboration with Planning and HR to improve site run strategy and staffing, improving organizational effectiveness, resulting in a 9.6% increase in attainment, a 23% increase in Output Reliability, and a greater than 97% dispatch rate (service).
  • Drove operational excellence across Operations and Maintenance to achieve an 18% increase in site OEE, and a 20% decline in waste over the last 18 months. This resulted in additional capacity to insource volume from CMs, and zero outsourcing due to performance.
  • Successfully integrated a +$8 million Capex project, insourcing Bouillon into factory operations through cross-functional collaboration with internal and external stakeholders.
  • Conducted root cause analyses to address safety, quality, and throughput challenges. The site achieved zero recordable injuries over the last two years, and has maintained single-digit CCPMUs. Championing safety and quality culture, supporting CSHEC and Site Food Safety team initiatives.
  • Consistent delivery of team performance reviews, providing ongoing feedback and coaching, has enhanced productivity, employee growth, and multiple team members achieving internal promotions. Mentored multiple UFLs through successful hurdles.
  • Hosted monthly town halls to increase communication with hourly and salaried teams, to boost employee engagement, culture, and to align the team with business objectives. Participated in site engagement activities, round table actions, and the rollout of Unilever’s new 4 Behaviors as a trainer.

Manufacturing Excellence Manager

Unilever
Independence, MO
02.2022 - 09.2022
  • Drove continuous improvement initiatives with a team of five Process Engineers to enhance operational efficiency, standing up Run 2 Standard across five production cells.
  • Defined and facilitated the implementation of multiple process improvements and capital projects impacting OEE, attainment, OR, CPT, and waste.
  • Developed a strategic three-year Master Plan to elevate manufacturing performance and capabilities.
  • Conducted data collection, analysis, and reporting on plant performance metrics.

Site Processing Lead, Mix Processing & Lipton Tea

Unilever
Independence, MO
08.2018 - 02.2022
  • Led the Savory Process team to achieve year-over-year increases in OPE and attainment, as well as reductions in waste, man-hours per ton, and overtime.
  • Assumed additional operational responsibility for the DF area, overseeing up to 115 direct and indirect reports. Governed POP expansion to DF, resulting in a reduction of 12 operators, and a $600,000 annual cost savings.
  • Implemented inventory control program for Savory Process, improving accuracy from 70% to 96.5%, yielding 37% waste reduction year-over-year.
  • Supported multiple capital projects and continuous improvement initiatives within the department, including the Malto Supersack Conversion, Tower Load Cells, and SW Reduction Project with R&D.
  • Led Ergonomic Safety Team to mitigate high-risk tasks, driving significant 5S improvements in Savory Process.

SSG Lead, Knorr Savory Packaging

Unilever
Independence, MO
12.2017 - 08.2018
  • Led operations for SAT conversion on lines 8 and 9 to enable Sides product capability, and unlock more capacity.
  • Initiated Line 14 Resurgence Project with a cross-functional team to enhance performance and reduce waste. Achieved 44% OEE in January through focused improvements after an initial OEE drop to 24% the month prior.
  • Ensured service levels were met for Canadian business by achieving 10,000 cases weekly through soup season on L12 and L13, through staffing, and operational enhancements. Collaborated with maintenance team and WCM to address top losses, improving safety and efficiency during roll changes.
  • Operationally supported line 11, a $1.2 million capital project, to boost capacity and OEE. Resulting in an OEE increase from 19.1% to a monthly high of 48.1%, finishing the year at 31.5% OEE.
  • Co-led the Safety Incident Investigation Team's actions to enhance floor engagement, facilitate complex investigation completion, and learnings across the site.

Manufacturing Supervisor, Knorr Savory Packaging, A, B, & D Shift

Unilever
Independence, MO
08.2017 - 12.2017
  • Led onboarding efforts for over 20 employees alongside HR team during mass hiring phase. Developed comprehensive onboarding plan for operations team, coordinating execution with shift supervisors.
  • Supported packaging achievement of one million cases per week in September 2017 by improving performance and daily shift attainment on the night shift.
  • Addressed operational gaps by implementing FOS through regular huddles and GEMBA walks.
  • Increased lead and operator engagement to boost overall team morale.
  • Co-led Indy-Pendence Day event to promote safety for returning associates post-holiday shutdown.

Supervisor of Manufacturing Operations, Rimfire

Orbital ATK/Vista Outdoor
Anoka, MN
04.2007 - 08.2017
  • Held progressive roles in ammunition manufacturing across two different sites within the company. Relocated from Independence, MO, to Anoka, MN. The positions held range from Operations Technician A to Supervisor of Manufacturing Operations.
  • Led a team of 45 associates and 2 line leads in a high-volume, high-explosive ammunition manufacturing environment.
  • Prioritized safety and quality through internal audits, incident investigations, and ensured adherence to ISO 9001 standards.
  • Implemented and sustained Lean Manufacturing principles throughout the value stream.
  • Collaborated with the Master Scheduler to ensure adherence to monthly schedules, balancing internal and external customer demands through Kanban and Heijunka boards.

Education

B.S. - Business Management

Western Governors University (WGU)
Kansas City, MO
01.2019

Associates of Arts -

Metropolitan Community College of Kansas City (MCCKC)
Independence, MO
01.2010

Skills

  • Servant leadership
  • Strategic planning
  • Operational excellence
  • Safety and quality champion
  • Performance management
  • Cross-functional collaboration
  • Continuous improvement
  • Talent development
  • Employee engagement
  • Inventory and budget control

Certification

  • Six Sigma White Belt

Languages

English
Full Professional

Timeline

Associate Director of Manufacturing

Unilever
09.2022 - Current

Manufacturing Excellence Manager

Unilever
02.2022 - 09.2022

Site Processing Lead, Mix Processing & Lipton Tea

Unilever
08.2018 - 02.2022

SSG Lead, Knorr Savory Packaging

Unilever
12.2017 - 08.2018

Manufacturing Supervisor, Knorr Savory Packaging, A, B, & D Shift

Unilever
08.2017 - 12.2017

Supervisor of Manufacturing Operations, Rimfire

Orbital ATK/Vista Outdoor
04.2007 - 08.2017

B.S. - Business Management

Western Governors University (WGU)

Associates of Arts -

Metropolitan Community College of Kansas City (MCCKC)

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