Gustave Dylla
Bayville,NJ
Summary
General Manager with over 25 years of manufacturing experience. Successfully started up two custom manufacturing facilities with full P&L responsibility. Set up and implemented 3 ERP Manufacturing/Accounting platforms. Extensive experience in consulting to improve processes on the factory floor along with extending that consulting to engage with upper management and their roles in the company’s operations and profitability. Analyzed and reengineered sales and maximized profitability in one company from sales of 2.2 million to 4.7 million within two years while keeping the same labor force. Full accountability for all strategic and business planning, customer service, production control, cost analysis, manufacturing metrics, engineering, materials management, purchasing, inventory control, and accounting.
Overview
22
22
years of professional experience
1
1
Certification
Work History
Consultant
Freelance
Bayville, NJ
06.2023 - Current
- Initially, I sat down with upper management to understand the company’s business goals and objectives.
- Conducted an in-depth analysis of the business operations, analyzing all data.
- Identifying where improvements can be made and risks that need to be addressed.
- Recommendations and solutions were made to meet the client’s needs and expectations.
- Identified issues in labor rates, BOMs, scrap rates, and work centers.
- Implemented changes and monitored their outcomes for effectiveness.
- Set up maintenance procedures for all company equipment, and worked with the Quality Manager in compliance with ISO 9001:2015 standards.
- Created plans to propose solutions to problems related to efficiency, costs or profits.
Cost Accounting Consultant
FK Instrument Co.
Tampa, FL
05.2023 - 06.2023
- Evaluated companies' initial costing structure and overhead within their current JobBOSS ERP database.
- Uncovered serious deficits in companies' setup files for JobBOSS, and corrected files.
- Identified and fixed irregularities in actual manufactured product costs in labor, BOMs, and outside services.
- Analyzed the collected data, and then developed a solution to begin fixing the ERP system to deliver metrics of 90%.
- Finalized with a detailed plan and approach to maintain the database structure in its corrected format.
General Manager
Urethane Innovators
New Bern, NC
01.2020 - 03.2022
- Increased polyurethane product sales by 35% by implementing lean manufacturing processes, addressing supply chain deficits, modifying tooling, and involving employee participation.
- Directed and developed all technical aspects for new product lines and tooling.
- Formulated custom polyurethane formulations.
- Upon hire, I fixed a failed new product launch with losses of $200,000 using a newly developed compound and process that created multi-million-dollar sales and new markets for the customers' products.
- Implemented a new cloud-based JobBOSS 2 ERP manufacturing platform to replace an outdated system.
- Increased production output by 40% with newly created BOMs, and detailed router operations and run rates.
- Formulated polyurethane formulations on the Baule 4-component polyurethane casting machine to automate the process, increasing daily production by 50% by dispensing 30A-85A custom mixes.
- Implemented a Preventative Maintenance Program for all machinery to reverse a company culture.
- Instituted labor recording on all operations through bar code readers in actual time to show 'True Profit and Loss.'
- Strategized company teams to work together in supporting, planning, and executing a positive customer experience.
- Recruited, interviewed and hired qualified staff for open positions.
Consultant
Dylla Manufacturing
Sea Girt, NJ
05.2014 - 12.2019
- Analyzed the company’s cost, quoting, quality, and other processes, and operational infrastructure to improve efficiency and profitability.
- Evaluated, set up, and implemented ERP manufacturing software systems with bar code readers to report actual versus estimated labor, to verify expected profit margins.
- Uncovered and fixed costing issues in estimating operations, materials, scrap rates, and work center efficiencies.
- Modified company policies to become compliant with OSHA, Right to Know, SDS, REACH, and ROHS.
- Identified areas for improvement, narrowing focus for decision-makers in making necessary changes.
- Oversaw quality control to identify inconsistencies and malfunctions.
- Audited company's legal documents to verify compliant policies and procedures.
- Provided advice on operational processes, ISO 9001/2015, business development initiatives, organizational changes and other areas of improvement.
Operations Manager
Precision Urethane & Machine Inc.
Hempstead, TX
07.2013 - 04.2014
- Evaluated and improved the company’s metrics from 59% to 92% in all product lines over nine months.
- Improved urethane injection molding processes with tight processing controls to increase profit margins by 20% to 25% and reduce scrap rates by 30%.
- Examined the work order flow to the production floor.
- Corrected severe errors in chemical formulas in Excel software.
- Recommended software changes to reduce personnel and work order creation time to the factory floor by 200% through new ERP software.
- Uncovered OSHA violations and made corrective actions.
- Implemented an employee training program to support the company in compliance.
- Established and evaluated new 1st Article Inspection procedures and guidelines for product lines.
General Manager
Dylla Manufacturing Co. Inc.
Spring Lake, NJ
01.2003 - 06.2013
- Successfully set up this start-up custom polyurethane manufacturing company venture through planning, staffing, and budgeting, from concept to full-scale operations.
- Set up and implemented the E2 Shop Tech ERP platform with full manufacturing and accounting functions.
- Streamlined operating infrastructure, replaced non-performing staff, and introduced automation and performance improvement initiatives throughout the manufacturing organization.
- Developed new manufacturing processes in custom rollers to enhance urethane formulations' physical properties in load-bearing properties, from an accepted 27% to a 6% compression set, while maintaining compliance with approved formulations.
- Automated manufacturing processes and equipment on a 1-million-dollar product line aim to reduce labor costs and increase company competitiveness in a tight market.
- Implemented new product lines, reduced costs, and increased profit margins through automation and cost accounting reporting.
Education
Six Sigma Green Belt Program
01.2025
Chemistry/Biology
Drew University
MadisonSeton Hall University
Skills
- JobBOSS
- E2 Shop Tech
- Preventive Maintenance
- Customer service
- Cost accounting
- Lean manufacturing
- P&L Management
- ERP Manufacturing/Accounting
- ISO 9001:2015
- Root Cause Analysis
- Process Optimization
- Supply Chain Management
- Estimating
Affiliations
- PMA - Polyurethane Manufacturer's Association
- New Jersey Business and Industry Association
Certification
- Basic Rubber Compounding and Processing
- Low Pressure Boiler License
Languages
- English
- Basic Spanish
Phone
cell, 732-298-3103
Timeline
Consultant
Freelance
06.2023 - Current
Cost Accounting Consultant
FK Instrument Co.
05.2023 - 06.2023
General Manager
Urethane Innovators
01.2020 - 03.2022
Consultant
Dylla Manufacturing
05.2014 - 12.2019
Operations Manager
Precision Urethane & Machine Inc.
07.2013 - 04.2014
General Manager
Dylla Manufacturing Co. Inc.
01.2003 - 06.2013
Six Sigma Green Belt Program
Seton Hall University
Chemistry/Biology
Drew University
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