Jeffrey Schuck
Lexington,KY
Summary
Operations leader with proven track record of leading teams in developing innovative solutions to solve complex business problems. Ability to create a strategic vision and project plans to achieve long-term business improvements. Skillful at using Lean Manufacturing principles and Six Sigma techniques to improve processes and increase profitability. Experienced in managing complex global supply chains.
Overview
30
30
years of professional experience
Work History
Senior Operations Consultant
Birmingham
07.2023 - Current
- Independent Consultant at a client’s facility in Birmingham, AL to develop World Class Manufacturing in a machining, welding, assembly, and pack operation
- During the initial 5 months of the project, increased throughput by over 30%, improved on-time delivery by 61%, and inventory reduction of 70% through implementation of Lean principles.
Director of Operations Optimization
CUMMINS-Meritor
Florence, KY
10.2022 - 07.2023
- Responsible for leading Continuous Improvement within Cummins-Meritor Global Aftermarket across remanufacturing and distribution centers in North America and Europe
- Completed Value Stream Mapping workshops in North American sites and leading cross-functional Kaizen teams to execute projects toward Future State vision
- Launched VSM activity in European distribution operations
- Participating on Cummins Global Integration team to achieve $150M targeted synergy savings by optimizing distribution and logistics and leveraging global supply chains.
Director of Product Management
CUMMINS-Meritor
01.2019 - 01.2022
- Led team of Product Managers responsible for managing product lines with over 400 million in revenue
- Increased market share in strategic growth products by expanding product portfolio to replace competitor’s products in the field and supported by marketing programs to generate ongoing revenue
- Led Product team in achieving $20+ million in strategic growth initiatives over past 3 years
- Challenged to solve numerous supply chain disruptions to maintain customer service levels.
Owner/GM
CONSERVA IRRIGATION
Lexington, KY
10.2017 - 05.2019
- Achieved nearly $100K in revenue and acquired 150 new customers in our first season of business
- Participated on national team to achieve prestigious industry award for water saving project at Target Stores.
Segment Business Leader
Motor Wheel (Stemco / Hayes Lemmerz)
Berea, KY
01.2013 - 01.2017
- Responsible for overall management of STEMCO Crewson business unit
- Oversaw the final phase of the acquisition from joint venture partner and led the integration of the Buffalo operation into STEMCO Berea
- Product line revenue increased 64% after experiencing flat growth in the two years prior to 2013
- Introduced new commercial programs to grow aftermarket sales by 20%
- Led successful relocation of operation from Buffalo, NY generating nearly $400K in OI improvement
- Awarded standard position at a major trailer OEM and coordinated the successful product launch and training at 7 different customer facilities.
Director of Operations
Motor Wheel (Stemco / Hayes Lemmerz)
Berea, KY and Chattanooga, TN
01.2008 - 01.2013
- Site leader for Motor Wheel operations which consists of 364,000 ft2 foundry, machining, assembly, and distribution operations in Berea, KY and Chattanooga, TN
- Assigned as overall project leader to develop a new Distribution Center for all STEMCO products
- Led a cross-functional team of 20 people across each of the five manufacturing sites to create new distribution center within existing Berea facility
- Spearheaded the implementation of Lean to restructure the operations to improve processes and increase profitability
- Increased EBITDA margins by 57% despite a 30% decline in overall sales by reducing overall operating expenses by $6M and increased plant productivity by nearly 38%
- Led project to reduce purchased cost of metal stamping component by 20%
- Completed 12 months without an outgoing quality defect and 3 years without a safety incident
- Doubled inventory turns while maintaining customer service levels above 97%
- Facility was recognized by an outside consulting company as a benchmark for Lean practices.
Director of Engineering
Motor Wheel (Stemco / Hayes Lemmerz)
01.2006 - 01.2007
- Led product development and manufacturing engineering functions at four locations in US and Mexico
- Responsible for product testing and validation of wheel-end components
- Successfully coordinated the startup of a manufacturing partner in China resulting in the qualification of a new line of Trailer Hubs
- Implemented a new $900K robotic welding process with significant product improvement
- Led project to develop a new assembly process achieving 70% improvement in drum balance.
Engineering Manager
Motor Wheel (Stemco / Hayes Lemmerz)
01.2003 - 01.2005
- Responsible for all plant engineering activities and leading Operational Excellence implementation across five facilities in US and Mexico
- Instrumental in deploying new corporate wide Lean Belt training program
- Successfully completed over $1.5M in capital improvement projects
- Led strategic Business Unit taskforce to improve profitability of hub and drum product lines in US and Mexico operations, resulting in $2.3 million annual cost savings
- Achieved Black Belt certification with project to reduce machining cycle time of new truck hub by 50%; mentored 20+ Six Sigma candidates.
Supply Chain and Continuous Improvement Manager
Motor Wheel (Stemco / Hayes Lemmerz)
01.2002 - 01.2003
- Managed a $30 million automotive aftermarket operation and key member of corporate team to launch Operational Excellence initiative at 19 North American facilities
- Coordinated Lean/Six Sigma training for 500+ associates at 5 locations
- Restructured aftermarket business and increased OI by 50% integrating distribution operations and transferring production to lower cost regions in South America and Asia
- Launched two new digital brake controllers with investment payback in under 6 months
- Increased on-time delivery by 30%, while also increasing inventory turns by 55%.
Industrial Engineer
Flextronics (Solectron)
Charlotte, NC
01.2000 - 01.2002
- Provided equipment and labor capacity analysis for entire Charlotte campus, which included 3,500 associates and 750,000 sq-ft of manufacturing space
- Successfully completed over $4M in capital projects to support business growth
- Streamlined and improved processes for capacity planning, pricing, and production scheduling.
Business Center Manager, Lean Manufacturing
Honeywell (AlliedSignal)
Greenville, OH
01.1998 - 01.2000
- Facility leader for Lean implementation in high-volume auto component facility
- Achieved first Lean Expert certification within the division
- Conducted Lean value stream analysis and completed multiple Lean projects in Heavy-Duty Filter business resulting in annual operations savings of more than $900,000
- Utilized Six Sigma tools to reduce scrap by 25% and increase output by nearly 15% in bottleneck operation.
Associate Operations Engineer
Rockwell Automation
01.1994 - 01.1996
- Two-year leadership program consisting of four six-month manufacturing positions.
Director of Supply Chain/Business Process Excellence
Motor Wheel (Stemco / Hayes Lemmerz)
Berea, KY
01.2017
- Divisional leader for all STEMCO Supply Chain activities along with leading Operational Excellence initiatives for the company
- Oversaw the reorganization of Supply Chain teams to align purchasing and planning functions
- Project leader for $2.5M capital project to consolidate manufacturing operations across 5 sites in US and Mexico to better utilize manufacturing footprint and improve customer service for key products.
Manufacturing Unit Leader
Rockwell Automation
Twinsburg, OH; Dublin, GA
- Supervised a team of 30 associates, engineers and technicians in final assembly and test operation
- Improved repair and rework process resulting 75% reduction in outgoing quality defects.
Education
Master of Science in Manufacturing Management -
Kettering University
Bachelor of Science in Electrical Engineering -
Purdue University
Skills
- Product Management
- Lean Manufacturing
- Project Management
- Six Sigma
- P&L Responsibility
- Operating Budgets
- Business Restructuring
- Supply Chain Optimization
- New Product Development
- Capital Projects
- Team Development
- Life Cycle Management
- Sales & Operations Planning
Personal Information
Title: Lean Expert Certification (Lean Alliance)
Timeline
Senior Operations Consultant
07.2023 - Current
Director of Operations Optimization
CUMMINS-Meritor
10.2022 - 07.2023
Director of Product Management
CUMMINS-Meritor
01.2019 - 01.2022
Owner/GM
CONSERVA IRRIGATION
10.2017 - 05.2019
Director of Supply Chain/Business Process Excellence
Motor Wheel (Stemco / Hayes Lemmerz)
01.2017
Segment Business Leader
Motor Wheel (Stemco / Hayes Lemmerz)
01.2013 - 01.2017
Director of Operations
Motor Wheel (Stemco / Hayes Lemmerz)
01.2008 - 01.2013
Director of Engineering
Motor Wheel (Stemco / Hayes Lemmerz)
01.2006 - 01.2007
Engineering Manager
Motor Wheel (Stemco / Hayes Lemmerz)
01.2003 - 01.2005
Supply Chain and Continuous Improvement Manager
Motor Wheel (Stemco / Hayes Lemmerz)
01.2002 - 01.2003
Industrial Engineer
Flextronics (Solectron)
01.2000 - 01.2002
Business Center Manager, Lean Manufacturing
Honeywell (AlliedSignal)
01.1998 - 01.2000
Associate Operations Engineer
Rockwell Automation
01.1994 - 01.1996
Manufacturing Unit Leader
Rockwell Automation
Master of Science in Manufacturing Management -
Kettering University
Bachelor of Science in Electrical Engineering -
Purdue University
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