Job Search Status
Open to workDesired start date: Flexible
Desired Job Title
Plant ManagerPlant DirectorGeneral ManagerWork Type
Full TimeLocation Preference
On-SiteLocation: Hot Springs Village, USA, US
Open to relocation: No
Open To Work
Jerry Fletcher
Hot Springs Village,USA
Work Preference
Summary
Senior Management professional with 40 years in manufacturing, specializing in lean operations and profitability enhancement. Proven expertise in managing fabrication processes, optimizing workflows, and improving team performance. Achievements include substantial cost reductions through resource efficiency and process enhancements, while upholding quality and safety standards. Strong leadership skills supported by extensive knowledge of machinery operation and industry best practices.
Overview
43
43
years of professional experience
Work History
Maintenance Manager
Amcor
Hot Springs, USA
09.2023 - Current
- Oversaw facility and machine maintenance for two plants, achieving 25% improvement in OEE.
- Managed annual maintenance budget of 4.6 million, ensuring efficient resource allocation.
- Implemented preventive maintenance program, resulting in increased operational reliability.
- Boosted plant OEE from 50% to 80% through targeted efficiency initiatives as of May 2025.
- Controlled Parts Room and Machine Shop operations, enhancing in-house parts production capacity.
- Transformed Machine Shop into a profit center by expanding repair capabilities and services.
- Negotiated with new provider for Parts Room, enforcing access restrictions to control costs.
- Achieved 40% reduction in consumables and PPE supply costs through strategic sourcing efforts.
Field Service Engineer
Prima Power North America
Arlington Heights, USA
03.2017 - 09.2023
- Installed and serviced Prima Power sheet metal fabrication systems.
- Specialized in Night Train systems to enhance operational efficiency.
Corporate Director of Operations/Plant Manager
Sag-Mecasa
Santa Catarina, Mexico
01.2014 - 03.2017
- Managed operations across two plants, overseeing Production, Engineering, and Maintenance functions.
- Implemented best practices and developed Lean Manufacturing processes in Mexico City facility.
- Reviewed headcount and capabilities to expand operational efficiency while reducing overhead costs.
- Executed comprehensive process reviews and implemented 5S methodologies for improved organization.
- Maintained role of Plant Manager with a focus on operational excellence and team leadership.
Plant Manager
Sag-Mecasa/Promesa
Santa Catarina, Mexico
06.2011 - 01.2014
- Managed daily operations for two companies, ensuring efficient workflow and client satisfaction.
- Achieved 20% production increase while reducing headcount by 20% within six months.
- Executed financial planning and Lean Manufacturing initiatives to enhance cost efficiency.
- Implemented ERP system to streamline processes and improve data accuracy.
- Led TS-16949 Certification process, resolving all minor CARs within 20 days.
- Maintained shipping compliance at 100%, achieving zero overtime in 2015.
- Doubled production over two years without increasing headcount or capital expenditure.
- Recognized as eligible for Daimler 'Master of Quality' award in 2015.
Engineering Manager
DBG Services, S.A. de C.V.
Apodaca, Mexico
04.2008 - 05.2011
- Managed four departments including Plant Engineering, Project Engineering, Tool Room, and Maintenance with 10 direct and 46 indirect reports.
- Oversaw operations for two plants: Manufacturing and Modular Assembly, optimizing productivity.
- Led Lean Manufacturing initiatives, implementing TMS, 5S, Kanban, and Value Stream Mapping to enhance efficiency.
- Redesigned Fabrication layout, reducing unscheduled overtime from 1100 to 300 hours weekly.
- Supervised international product transfers and new product development using APQP and PPAP processes.
- Monitored QIS against actual performance to ensure rate compliance and improvement.
- Conducted time and motion studies to streamline processes and boost capacity reports.
- Designed and fabricated inspection and welding fixtures to support production quality standards.
Operations Manager
Grupo Metal Intra, S.A. de C.V.
San Juan del Rio, Mexico
04.2004 - 04.2008
- Oversaw daily operations of manufacturing facility with 450-500 employees.
- Managed all aspects of manufacturing and fabrication.
- Formulated and maintained annual budget for three companies, including capital expenditures and P&L.
- Negotiated contracts with suppliers and clients to ensure competitive pricing and service agreements.
- Implemented corporate-wide software system, transitioning from Excel to an integrated ERP solution.
- Reduced monthly consumable costs by 40% through strategic procurement and efficiency initiatives.
- Reported regularly to principles on financial performance and operational metrics.
- Collaborated with Corporate Planning team on long-term strategic development initiatives.
Steel Fabrication Manager
ALP Lighting Products, S.A. de C.V.
Apodaca, Mexico
09.2000 - 03.2004
- Revitalized obsolete production system, achieving high output for standard product lines without operators.
- Oversaw engineering, maintenance, and programming departments with 7 direct and 35 indirect reports.
- Managed plant layout, process improvements, and departmental budgets to optimize operations.
- Executed capital expenditure recommendations and justifications to support strategic initiatives.
- Provided technical support, production scheduling, and maintenance assistance across the facility.
- Delivered programming and training for FMS cell operators, ensuring operational efficiency.
- Coordinated new equipment transfers and installations across five assembly lines and multiple forming cells.
Field Service/Application Engineer
LVD/Strippit Corporation
Buffalo, USA
08.1997 - 09.2000
- Delivered service and application support for Press Brakes, Turret Presses, Lasers, and FMS cells nationwide and in Latin America.
- Specialized in automated Flexible Manufacturing Cells integrating raw sheet storage with component completion controlled by one PC.
- Educated clients on optimal equipment utilization to maximize production efficiency.
- Facilitated 24-hour Lights Out operations for customers through integrated manufacturing solutions.
Plant Manager
GLC Engineering, Inc.
Elmhurst, USA
02.1995 - 06.1997
- Managed daily operations of facility, ensuring high-quality output and efficiency.
- Achieved 100% on-time delivery rate within six months in this role.
- Oversaw purchasing, scheduling, HR duties, and P&L responsibilities with monthly reports.
- Implemented CAD/CAM software to automate programming processes.
- Led strategic acquisition of new CNC cells, reducing labor costs by 50%.
- Maintained compliance with precision standards using CNC work centers and robotic welding.
- Supervised administrative tasks and engineering functions in a small team environment.
- Collaborated with major clients, including GM, Ford, Motorola, and Rockwell-Collins.
Production Manager
Keener Corp.
Connersville, USA
04.1993 - 02.1995
- Designed and supplied shipping racks for major automotive manufacturers including Ford, Chrysler, and GM.
- Managed daily production activities with six direct reports and 60 indirect staff.
- Ensured all material requirements aligned with customer demand to optimize supply chain efficiency.
- Maintained labor efficiency and production processes to meet manufacturing estimates.
- Oversaw inventory and work-in-progress costs to remain within budgetary projections.
- Achieved 99% on-time delivery with minimal overtime through innovative scheduling methods.
Journeyman Sheetmetal Worker
Various HVAC Contractors & USAF
06.1983 - 03.1993
- Executed sheet metal fabrication and installation for HVAC systems.
- Maintained adherence to safety standards during all operational processes.
Education
Associates Degree - Meteorology
USAF
Chanute AFB, Il05.1981
High School - General Studies
LDF High School
LeGrand, IA05.1979
Some College (No Degree) - Sheet Metal Fabrication
Union Sheet Metal Apprenticeship
Rock Island, ILSkills
- Spanish bilingualism
- Budget management and cost control
- Operational efficiency
- Lean manufacturing and process improvement
- Parts and inventory management
- Team leadership and staff management
- Project management and scheduling
- Supplier negotiation and relationship management
- Time management and prioritization
- Problem solving and critical thinking
- Effective communication skills
- Employee training and performance assessment
- Energy management strategies
- Installation and maintenance management
- Expense tracking and budgeting
Languages
Spanish
Native/ Bilingual
Timeline
Maintenance Manager
Amcor
09.2023 - Current
Field Service Engineer
Prima Power North America
03.2017 - 09.2023
Corporate Director of Operations/Plant Manager
Sag-Mecasa
01.2014 - 03.2017
Plant Manager
Sag-Mecasa/Promesa
06.2011 - 01.2014
Engineering Manager
DBG Services, S.A. de C.V.
04.2008 - 05.2011
Operations Manager
Grupo Metal Intra, S.A. de C.V.
04.2004 - 04.2008
Steel Fabrication Manager
ALP Lighting Products, S.A. de C.V.
09.2000 - 03.2004
Field Service/Application Engineer
LVD/Strippit Corporation
08.1997 - 09.2000
Plant Manager
GLC Engineering, Inc.
02.1995 - 06.1997
Production Manager
Keener Corp.
04.1993 - 02.1995
Journeyman Sheetmetal Worker
Various HVAC Contractors & USAF
06.1983 - 03.1993
Associates Degree - Meteorology
USAF
High School - General Studies
LDF High School
Some College (No Degree) - Sheet Metal Fabrication
Union Sheet Metal Apprenticeship