James Merkel
Fort Wayne,IN
Summary
Operations professional with proven track record in optimizing processes and driving efficiency. Strong focus on team collaboration, strategic planning, and achieving measurable results. Adapting to changing needs and leading cross-functional teams. Skilled in project management, process improvement, and resource allocation. Dependable and results-driven, known for enhancing operational performance.
Overview
34
34
years of professional experience
Work History
Operations Manager
J. O. Mory
07.2020 - Current
- Safety review and continuous safety improvements; to ensure the best environment for our employees
- Managing a staff of 100 or more, from Ohio to Texas
- Responsible for scheduling personnel, equipment and customer base
- Recruiting and on boarding personnel
- Senior management team; which actively aids in all company decision making
- Customer support through direct interaction to include estimating, quoting and execution of projects
- Empowered employees to take ownership of their responsibilities, leading to increased accountability and improved performance outcomes.
- Conducted regular performance reviews, identifying areas for improvement and developing action plans to address them.
- Led hiring, onboarding and training of new hires to fulfill business requirements.
- Enhanced customer satisfaction by establishing clear communication channels and addressing concerns promptly.
- Achieved higher employee retention rates by fostering a positive work environment and providing opportunities for professional growth.
- Interacted well with customers to build connections and nurture relationships.
Steel Door Operations and Compounding Focus Factory Manager
Therma Tru Doors
11.2011 - 06.2020
- Direct report to the Plant Manager of the company
- Lead weekly War Room meeting with all cross functional departments of the plant, to improve performance in areas of responsibility
- Lead the DDI Leadership essentials training in all facilities for Group Leaders through Plant Managers (24 hours training)
- Lead process improvement teams, utilizing my Six Sigma Black Belt, KATA, PDCA, 5S Trainings
- Build 17k steel door slabs a week
- Daily responsibilities included:
- Safety incident review, investigation, and corrective actions as applicable
- Managing to Schedule and Operations Plan (S&OP)
- Manage labor moves to attain efficiency budget
- Measure to an OEE in all subordinate areas
General Manager
Riverside Manufacturing
03.2011 - 11.2011
- Direct report to the President of the company.
- Lead monthly Kaizen Projects driving continuous improvement projects in all facilities.
- Daily responsibilities include:
- Develop and execute production schedule plan
- Assure daily scheduled shipments to plan
- First interface with customers to address design and quality issues
- Address supplier with tardy schedules, along with design and quality issues
- Develop and coordinate training activities for direct labor associates
- Weekly responsible for reports on project activities, labor utilization, scheduling of fixed assets, effectiveness of material flow thru the facility with inventory turns.
Plant Manager
Riverside Manufacturing
06.2010 - 03.2011
- Direct report to the General Manager
- Returned to Huntertown to facilitate merger with Transportation Safety Technologies division into the Huntertown Facility.
- Did planning groundwork for materials ordering, inventory, and parts flow implementation to blend different product lines into an efficient flow through the facility.
- Responsible for all plant manager normal daily responsibilities including:
- Executing a production schedule
- Maintaining all scheduled shipments
- Interface with customers and suppliers to address all normal manufacturing concerns
- Develop and implement training activities for direct labor associates
Plant Manager
Riverside Manufacturing
01.2009 - 06.2010
- Direct report to the General Manager
- Moved to the Kendallville location to facilitate and stabilize the move of operations from Ligonier, Indiana to Kendallville, Indiana
- Established the business plan for personnel and fixed assets
- Pivotal in the necessary efficiencies that afforded the organization to reduce existing labor through process improvements and expectations
- Successfully completed the second plant layout expansion totaling 25,000 square feet since January 2010
- Responsible for all plant manager daily responsibilities including:
- Executing a production schedule
- Maintaining all scheduled shipments
- Interface with customers and suppliers to address all normal manufacturing concerns
- Develop and implement training activities for direct labor associates
Global Quality Director
Riverside Manufacturing
01.2008 - 01.2009
- Direct report to the President of the company
- Assume the role of quality director in which I was tasked with developing the personnel and creating appropriate tiers of departmental infrastructure
- Infrastructure to manage customer and vendor concerns and continuous improvement
- Develop and improve quality standards, policies, and procedures
- Team member to lead with measurable and sustainable improvements
Plant Manager
Riverside Manufacturing
09.2004 - 01.2008
- This was a newly created position for a rapid growing company. Object was to establish SOP for all aspects of manufacturing to include:
- Materials, Manufacturing, Quality, Time standards, Cell layout work instructions, protocol for customer interface, and shipping
- Tracking graphs were developed and implemented for visual aides to associates, and measurement tools for senior management team
Business Unit Manager
Sidler
02.2003 - 09.2004
- Assigned responsibilities to representing Ford and all foreign customers
- Managing a support staff of:
- Process engineering
- Quality engineering
- Production scheduling
- Productions supervisors
- 43 assembly associates
- Utilize daily contact with OEM customers to ensure the integrity of interior components and wire harnesses. Use my managerial experience in problem solving, continuous improvement, lean manufacturing, motivation, training and coaching to help meet production cost schedules and quality requirements.
Production Scheduler
Cooper Standard Automotive
07.1998 - 02.2003
- Responsible for orders placed to all material vendors as well as scheduling shipments to all major automotive manufacturers
- Responsible for molding manufacturing, finishing and in the utility area
- Cost reductions led through implementation of Kaizen projects
- Production Supervisor of 30 associates
- Lean Manufacturing Certified
- QS9000 Third Addition Certified Internal Auditor
Distribution Supervisor
Stride Rite Co.
05.1997 - 07.1998
- Supervise 70 associates
Transportation and Logistics Supervisor
Ingram Distribution Co.
10.1992 - 05.1997
- Supervise 40 Associates
Warehouse Coordinator
Advantage Services INC. (ASI) Guardian Industries
06.1992 - 10.1992
- Responsible for daily inventories and employees
- Conduct forklift training and testing
Production Supervisor
Advantage Services INC. (ASI) Guardian Industries
08.1991 - 06.1992
- Responsible for the direct supervision of ASI line
Education
Six Sigma Black Belt
Purdue University
Fort Wayne, IN01.2013
OSHA Compliance Certified - undefined
Fort Wayne, IN01.2006
Business Administration, Business Management
Grand Valley State University
Allendale, MI01.1990
Business Management, Political Science
Ferris State University
Big Rapids, MI01.1988
Northwestern School of Taxidermy (14 Years of Age)
Omaha, NE01.1983
Skills
- Strong leader, communicator, motivator, and team builder
- Friendly, fair, firm… challenges can be resolved in a friendly manner
- Three main work rules
- Everyone must be treated with dignity, respect, and courtesy
- Motivational team builder
- Everyone wants to be somebody
- Everyone wants to contribute
- Everyone wants to be recognized
- Promote free thinking, employee involvement and empowerment, while still in charge
- Strong personal work ethic that drives team building and adherence to expectations
- Gifted with organizational skills, processes, equipment knowledge, and problem solving
- Excellent interaction and communication both up and down organizationally
- High energy level to do whatever it takes to get the job done
Accomplishments
- Team launches with APQP, Control plans, PFMEA, Work Instructions, Root Cause Analysis
- In-process PPM reduced from average 2005 of 19,455 PPM to 2,654 PPM through May 2008
- Final Inspection PPM reduced from average 2005 of 5,741 PPM to 436 PPM through May 2008
Hobbies
Woodworking, hunting, fishing and taxidermy
From a very young age I started carving waterfowl and fish from blocks of wood. I enjoy the outdoors so hunting and fishing became an easy hobby to pick up which led to my desire to learn how to taxidermy.
Timeline
Operations Manager
J. O. Mory
07.2020 - Current
Steel Door Operations and Compounding Focus Factory Manager
Therma Tru Doors
11.2011 - 06.2020
General Manager
Riverside Manufacturing
03.2011 - 11.2011
Plant Manager
Riverside Manufacturing
06.2010 - 03.2011
Plant Manager
Riverside Manufacturing
01.2009 - 06.2010
Global Quality Director
Riverside Manufacturing
01.2008 - 01.2009
Plant Manager
Riverside Manufacturing
09.2004 - 01.2008
Business Unit Manager
Sidler
02.2003 - 09.2004
Production Scheduler
Cooper Standard Automotive
07.1998 - 02.2003
Distribution Supervisor
Stride Rite Co.
05.1997 - 07.1998
Transportation and Logistics Supervisor
Ingram Distribution Co.
10.1992 - 05.1997
Warehouse Coordinator
Advantage Services INC. (ASI) Guardian Industries
06.1992 - 10.1992
Production Supervisor
Advantage Services INC. (ASI) Guardian Industries
08.1991 - 06.1992
Six Sigma Black Belt
Purdue University
OSHA Compliance Certified - undefined
Business Administration, Business Management
Grand Valley State University
Business Management, Political Science
Ferris State University
Northwestern School of Taxidermy (14 Years of Age)
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