Summary
Overview
Work History
Education
Skills
Accomplishments
Timeline
Section name
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Dennis Whitaker

Millington,MD

Summary

Dynamic management professional with a distinguished 35-year career marked by exceptional performance and measurable achievements. Extensive expertise in manufacturing, utilizing methodologies such as SMED, Lean Manufacturing, and advanced problem-solving techniques to enhance operational efficiency. Proven track record in human resources management, including staff scheduling, performance evaluations, and individual counseling in both unionized and non-union environments. Committed to fostering talent through effective mentorship and promoting a culture of continuous improvement, driving business growth while achieving operational excellence.

Overview

25
25
years of professional experience

Work History

General Manager

NELSON MILLER GROUP (INJECTION WORKS)
10.2023 - Current
  • Company Overview: Injection Works has been providing injection molding and related services to our customers for over 30 years by solving complex challenges in design, engineering, sourcing, custom manufacturing, and supply chain management.
  • The General Manager is responsible for all operations inside the plant and Full P&L using continuous improvement techniques consistent with company policies, customer service and plant objectives.
  • Daily management-initiated reviewing / build plant level KPIs that align with strategic objectives.
  • Plant Growth of 54% in 1.3 years while improving relationships between current customer base
  • Addressed cycle times across the plant and assembly areas.
  • Addressed pay scale to promote top tier talent.
  • Installed plant door security for the location to drive ITAR requirements.
  • Working with Engineering teams to build the company solution to faster quoting times.
  • Rebuilding plant safety systems.
  • Onboarding and training a new management team.
  • 10% increase in OEE since the new team has been in place.
  • Meeting with all customers and vendors to update terms to change the location from 12-month blanket orders to a more predictable sales forecast model.
  • Onboarding a new 10MM customer with class 7 cleanroom build requirements

Interim Plant Production Manager (Unionized Plant)

GRAHAM PACKAGING COMPANY
01.2011 - Current
  • Company Overview: Graham Packaging Company is a worldwide leader in the design, manufacture, and sale of custom blow-molded rigid plastic containers.
  • The Production Manager is responsible for the overall management of the production activities within the facility using continuous improvement techniques consistent with company policies, customer service and plant objectives. In addition, the Production Manager oversees the Production Supervisors and assigned personnel in the production and planning areas.
  • Lead Assumed Production manager duties to fill unexpected Vacancy. Initiated steps to address performance shortfalls and turn around a struggling operation.
  • Fostered Increased MOEE from 46.3% (July) to 60.8% (October).
  • Increased machine effectiveness from 78% of budgeted rate in July (80% YTD) to 89% of budgeted rate in October (Nov MTD 97%).
  • Turned a $41,000 monthly raw material loss (July) into a 3,000 gain (October).
  • Decreased negative cost of operations variance (Cost Ops) from -$251,000 in July to -$66,000 in October.
  • EBITDA YTD-July 31.8% of budget to Aug-Oct 66.1%
  • Monitor line & equipment performance and implement PM procedures.
  • Work closely with the Quality Manager to ensure all procedures are followed and monitored for process accordance & effectiveness.
  • Initiate corrective/preventive and continuous improvement opportunities through defined/document channels.
  • Maintain 5S standard throughout the plant.

Plant Manager

BERRY GLOBAL COMPANY
10.2022 - 10.2023
  • Company Overview: Berry Global company is a worldwide leader in plastic pails and lids and other products.
  • The Plant Manager is responsible for all operations inside the plant and Full P&L using continuous improvement techniques consistent with company policies, customer service and plant objectives.
  • Rebuild the safety systems in the plant around LOTO.
  • Onboarding and training new management team.
  • Increased EFF from low eighties to 92%.
  • Upgraded front office.
  • Many 5S projects across the plant.
  • Reduction of force managed for the plant due to volume drop.
  • Rebuilding the management team and installing front line leadership.

Plant Manager

GRAHAM PACKAGING COMPANY
01.2019 - 01.2022
  • Company Overview: Graham Packaging Company is a worldwide leader in the design, manufacture, and sale of custom blow-molded rigid plastic containers.
  • The Plant Manager is responsible for all operations inside the plant and Full P&L using continuous improvement techniques consistent with company policies, customer service and plant objectives.
  • Upgraded the front office lighting to get rid of mold throughout office spaces.
  • Restrooms upgraded for ADA compliance.
  • Doubled the expected AOP during 2020 earning 150K per team member to the bottom line.
  • It turned around 3.5 million in HFI inventory while collaborating with the customer to change the view of the location.
  • Upgraded plant lighting to LED.
  • Put in a fire system for the plant and repair the fire pump.
  • No way to get bottles back onto the line for Slimfast so we bought a bingo ink machine and built new tooling to run the Slimfast back onto the line reducing the labor need by 3 people.
  • Supporting the Newark location in an OHSA hearing receiving no citations or after-action reports.
  • Hired on and boarded four new Supervisors as well as Maintenance Manager, Production Manager, HR, and Quality Managers.
  • Put in tier one and two processes for the plant to build accountability and standard work.
  • Received positive feedback from all customers regarding the change in service at the end of 2020.
  • Last location within my company to have a Covid-19 impact.
  • Put in 5y problem solving on the floor to get the most out of the floor staff by way of troubleshooting.

Plant Manager

GRAHAM PACKAGING COMPANY
01.2016 - 01.2019
  • Company Overview: Graham Packaging Company is a worldwide leader in the design, manufacture, and sale of custom blow-molded rigid plastic containers.
  • The Plant Manager is responsible for all operations inside the plant and Full P&L using continuous improvement techniques consistent with company policies, customer service and plant objectives.
  • Turned around a negative perception at C&D, the only customer for the NKC plant.
  • In 2015 the NKC plant was losing volume due to failing to qualify push in spout bottles. This problem was corrected in 2016 when we completed and qualified over 20 SKU’s.
  • In 2016 the NKC plant was cited twice by OSHA both citations we disputed and won by the Graham team resulting in no fines.
  • Reduced freight cost by 73% from ($424,871) in 2016 to ($126,366) 2018
  • Improved customer complaints over 2016 from seventeen complaints to one complaint in 2017 and one in 2018
  • Reduced the cost ops gap in the NKC plant from ($1,724) in 2015 to ($55) 2018.
  • Managed all union issues without the need for grievance.
  • Ran many improvements based on improving morale and working conditions for the NKC staff.
  • Implemented new standards around OPEX and Tier meetings.
  • Implemented a daily labor tracker for a tier one to help control labor spending and bring awareness to the staff.
  • Reduced scheduled downtime due to color changes by way of Kaizen by 20%.
  • Managed many high-level meetings between Graham Packaging and C&D

Production Manager (Unionized Plant)/ Plant Manager

GRAHAM PACKAGING COMPANY
01.2014 - 01.2016
  • Company Overview: Graham Packaging Company is a worldwide leader in the design, manufacture, and sale of custom blow-molded rigid plastic containers.
  • The Production Manager is responsible for the overall management of the production activities within the facility using continuous improvement techniques consistent with company policies, customer service and plant objectives. In addition, the Production Manager oversees the Production Supervisors and assigned personnel in the production and planning areas.
  • Asked to fill in for the Plant Manager position on October 2, 2015.
  • Zero recordable accidents from Oct 2015 to July 31st of 2016.
  • Collaborated with the team on EBITDA to overcome the plant’s negative budget to an overall positive for the plant.
  • Worked with QA Manager and production team to reduce HFI (Hold Quantity/PPM), goal of 15.000 (2016) to an average of 9.978 PPM, zero Customer complaints and above goal on all quality audits.
  • Fostered Increased MOEE from 58.5% (YTD 2013) to 74.1% (End of July 2016).
  • On time and in full metric improved to 99% vs. Goal of 90%.
  • Maintained controls over virgin, PCR, regrind and colorant with SOC’s built for bottle types.
  • Managed labor reductions in the plant through layoffs in a unionized plant after 40% of the plants’ volume was lost.
  • Implemented Tier one meetings, hour by hour boards along with keeping key KPI’s out to aid my team members in the ownership of line performance.
  • Reduced changeover time by 50% to allow for more flexibility for the customer as well as better over cost for the company.
  • Worked with the leadership team to exceed our A3 commitments.
  • Held all Maintenance objectives above goal.

Production Manager (Unionized Plant)

GRAHAM PACKAGING COMPANY
01.2001 - 01.2014
  • Company Overview: Graham Packaging Company is a worldwide leader in the design, manufacture, and sale of custom blow-molded rigid plastic containers.
  • The Production Manager is responsible for the overall management of the production activities within the facility using continuous improvement techniques consistent with company policies, customer service and plant objectives. In addition, the Production Manager oversees the Production Supervisors and assigned personnel in the production and planning areas.
  • Collaborated with the team to drive EBITDA from $1,565,908 (2011) to $7,830,793 (2013).
  • Drove down Cost of Operations from -$1,824,716 (2011) to $2,040,959 (2013)
  • Drove down Conversion cost from $838.07 (2011) to $618.18 (2013).
  • Worked with QA manager and production team to reduce customer complaints from 45 (2012) to 12 (2013).
  • Worked with QA Manager and production team to reduce HFI (Hold Quantity/PPM) from 27.861 (2012) to 19.237 (2013).
  • Fostered Increased MOEE from 60.8% (October2011) to 68.5 (End of 2013).
  • Increased machine effectiveness to budget from 96.88 (2011) to 102.14 (2013).
  • Maintained controls over virgin, PCR, regrind and colorant with SOC’s built for bottle types.
  • Managed labor reductions in the plant through layoffs in a unionized plant.

Raw Materials Manager (Unionized Plant)

GRAHAM PACKAGING COMPANY
01.2008 - 01.2011
  • Company Overview: Graham Packaging Company is a worldwide leader in the design, manufacture, and sale of custom blow-molded rigid plastic containers.
  • Monitor all material levels within the facility including resin, regrind, PCR and color percentages. Ensure the plant has all the proper materials to always run production. Monitor daily usage of materials to meet plant budgeted goals.
  • Complete month-end inventories of all materials, analyze and report on variances. Develop action plans to promote continuous improvement and successful completion of goals and objectives.
  • Monitor month-end full inventory of all materials (including labels). Input information into SAP; analyze variances in detail on the last day of the month.
  • Coordinate miscellaneous materials shipments (labels, carton, etc.) to other facilities. Work with shipping and receiving departments on incoming and outbound shipments.
  • Developed improved SOC’s for the plant reducing the losses on all Raw materials with employee feedback and involvement.
  • Investigates low efficiency jobs to determine the cause of deficient performance.
  • Responsible for performing technical and project engineering duties to improve plant manufacturing performance, reduce costs, improve methods, and assist in machines maintenance and reliability.

Production Supervisor/Machine Operator (Unionized Plant)

GRAHAM PACKAGING COMPANY
01.2001 - 01.2008
  • Company Overview: Graham Packaging Company is a worldwide leader in the design, manufacture, and sale of custom blow-molded rigid plastic containers.
  • Responsible for the leadership of a production crew with regards to safety, quality, efficiency, and consistent application of best practices.
  • Provided a strong floor presence and understanding of the processes adequate to set an example for others to follow.
  • Managed day-to-day production documentation, ensured its accuracy and timely input into reporting systems.
  • Provided training to shift personnel to make sure all employees have the tools necessary for optimum performance.
  • Utilized data systems to identify areas of opportunity for continuous improvement.
  • Ensured that all products produced meet or exceed GPC and customer specifications. Oversaw the performance of all quality checks performed by associates.
  • Monitored all safety initiatives within the facility to ensure all safety goals and objectives are met, maintaining a safe work environment for all employees.
  • Managed routine issues with regards to employee relations.

Education

Associate - Science, Business Administration

Thomas Edison State University
Trenton, NJ

Certified Nursing Assistant - undefined

ESSEX COMMUNITY COLLEGE
Essex, MD
01.1998

General Studies - undefined

PATTERSON HIGH SCHOOL
Baltimore, MD
01.1995

Skills

  • Familiarity with CRM and ERP systems
  • Operations management
  • Leadership and team building
  • Problem resolution
  • Effective leader
  • Training and coaching
  • Staff management
  • Customer relations
  • Relationship building
  • Staff training
  • Goal setting
  • Verbal and written communication
  • P&L management

Accomplishments

  • Staffing - Worked directly with Human Resources to streamline hiring and onboarding process.
  • Achieved [Result] through effectively helping with [Task].
  • Documented and resolved [Issue] which led to [Results].
  • Achieved [Result] by completing [Task] with accuracy and efficiency.
  • Business Development: - Spearheaded acquisition of two competitor companies.Established and managed partner relationships on a daily basis. Developed new marketing strategy which increased customer base by 23%.
  • Supervision - Supervised sales team to monitor sales activity and goal achievement.

Timeline

General Manager

NELSON MILLER GROUP (INJECTION WORKS)
10.2023 - Current

Plant Manager

BERRY GLOBAL COMPANY
10.2022 - 10.2023

Plant Manager

GRAHAM PACKAGING COMPANY
01.2019 - 01.2022

Plant Manager

GRAHAM PACKAGING COMPANY
01.2016 - 01.2019

Production Manager (Unionized Plant)/ Plant Manager

GRAHAM PACKAGING COMPANY
01.2014 - 01.2016

Interim Plant Production Manager (Unionized Plant)

GRAHAM PACKAGING COMPANY
01.2011 - Current

Raw Materials Manager (Unionized Plant)

GRAHAM PACKAGING COMPANY
01.2008 - 01.2011

Production Manager (Unionized Plant)

GRAHAM PACKAGING COMPANY
01.2001 - 01.2014

Production Supervisor/Machine Operator (Unionized Plant)

GRAHAM PACKAGING COMPANY
01.2001 - 01.2008

Certified Nursing Assistant - undefined

ESSEX COMMUNITY COLLEGE

General Studies - undefined

PATTERSON HIGH SCHOOL

Associate - Science, Business Administration

Thomas Edison State University

Section name

  • Labor Relations Staff Recruitment & Retention Orientation & On-Boarding
  • Forklift Safety Employee Relations Training & Development
  • Accident Investigation Alternative Dispute Resolution (ADR) Performance Management
  • First Aid/CPR/AED Training Program/Project Management HR Policies & Procedures

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