Mark Feltner
PORT AUSTIN
Summary
Results-driven Senior Operations Manager with over 25 years of experience in manufacturing and consulting. Expertise in lean manufacturing, Six Sigma, process improvement, and strategic planning, driving operational excellence, cost reductions, and revenue growth. Adept at leading cross-functional teams, implementing Kaizen methodologies, and fostering collaborative environments for continuous improvement.
Overview
38
38
years of professional experience
Work History
MANAGEMENT CONSULTANT
Manufacturing Management Solutions
Port Austin
12.2019 - Current
- Reduced scrap rates by 20% and improved direct labor efficiency from 57% to 100% in 3 months
- Developed programs that yielded immediate revenue growth and cost reductions
- Led Lean Manufacturing initiatives to optimize processes and enhance teamwork
- Built strong stakeholder relationships to drive operational excellence
OPERATIONS MANAGER
Thumb Plastics, Inc
Bad Axe
09.2016 - 11.2019
- Managed 24/7 operations, leading 100+ employees in a multi-million-dollar facility
- Developed performance metrics to optimize inventory, staffing, and budgets
- Implemented Kaizen and 5S to reduce scrap and downtime, achieving measurable improvements
- Recruited and developed high-performing teams, enhancing productivity and quality
- Resolved personnel issues to support a productive work environment
PROJECT ENGINEER
S Group Automotive
Webberville
06.2013 - 09.2016
- Led launch of Tesla and Ford programs, enhancing tech integration and lifecycle management
- Directed product development, ensuring compliance and efficiency in design, and testing phases
- Facilitated solutions for major auto brands, meeting diverse engineering requirements
- Analyzed and improved design accuracy, improving production quality and consistency
- Implemented new processes, achieving measurable improvements in program outcomes
PLANT OPERATIONS MANAGER
US Farathane
Westland
01.2012 - 06.2013
- Led a staff of 170+ in lean transformation, cutting scrap percentage by 37%, boosting efficiency
- Standardized training, enhancing operations and raising customer satisfaction by 12%
- Created financial strategy for 30% growth, ensuring sustainable expansion
- Initiated a recycling program, generating $130,000 annually, saving $19,000 in costs
LEAN MANUFACTURING AND CONTINUOUS IMPROVEMENT MANAGER
Magna
Spartanburg
01.2009 - 01.2012
- Led lean manufacturing initiatives, achieving $243,000 savings by refining operations
- Implemented SMED, reducing changeover time from 2 hours to 30 minutes
- Collaborated with maintenance to set up a successful TPM program
- Exceeded savings forecasts consistently, achieving a 200% increase
- Developed and delivered training for lean manufacturing and continuous improvement
BUSINESS UNIT MANAGER
Magna
Spartanburg
03.2007 - 01.2012
- Coordinated business activities for overhead systems, enhancing team communication and efficiency
- Implemented Kaizen events, saving $479,000 by reducing waste and downtime by 70%
- Developed technical standards to guide performance and quality improvements
- Prepared strategic business plans to achieve annual growth goals
- Led training on lean manufacturing, fostering continuous improvement culture
SENIOR PROCESS ENGINEER
Magna
Howell
06.2002 - 03.2007
- Developed and optimized manufacturing processes for wet urethane headliners, Baypreg load floors, and assembly equipment
- Led process improvement initiatives to increase efficiency, reduced scrap costs by 33%, and improve product quality
- Collaborate with cross-functional teams, including production, maintenance, and quality, to troubleshoot and resolve process issues
- Design and implement process control systems to ensure consistent and reliable production
- Conducted process audits and reviews to ensure compliance with safety, environmental, and regulatory requirements
- Provide technical guidance and support to junior engineers and technicians
- Discover and implement innovative technologies and methodologies to improve processes and products
- Create and maintain process documentation, including standard operating procedures and work instructions
- Communicate with suppliers and vendors to identify and evaluate new equipment and materials that can improve processes and reduce costs
SENIOR PROCESS TECHNICIAN
Magna
Howell
10.1997 - 06.2002
- Managed urethane process setups and continuous improvement projects to meet production goals
- Monitored and documented process control parameters to ensure production standards were met
- Supported team members in achieving daily targets and contributed to process optimization initiatives
- Led a team of seventeen technicians in supporting and refining urethane processes across four departments
- Spearheaded process improvements, resulting in the achievements of all key operating indicators
- Oversaw technical operations during four product launches, ensuring quality and efficiency
MECHANIZED INFANTRY SQUAD LEADER
US Army
Ft. Polk
01.1990 - 02.1992
- Ensure the welfare, fitness, morale, and discipline of squad members
- Oversee the individual training and maintenance of equipment
- Direct the squad's tactical employment during offensive and defensive operations
- Coordinate with adjacent and support elements and organic and supporting firepower
- Analyze terrain and conduct tactical operations for the squad
- Maintain operational security and prepare secure communications equipment
SPECIAL DUTY NUCLEAR SECURITY INFANTRY TEAM LEADER
US Army
Heilbronn
08.1987 - 02.1990
- Led a team of infantry soldiers in nuclear security, ensuring mission success
- Coordinated strategic missions, resolving tactical challenges with measurable improvements
- Enhanced unit cohesion, leading to significant operational efficiency and mission success
- Resolved complex tactical challenges, achieving measurable results in high-pressure situations
Education
Skills
- Lean Manufacturing
- Six Sigma
- SMED
- Kaizen
- 5S
- TPM
- Budget Management
- Operations Management
- Quality Control
- Team Leadership
- Change Management
- Strategic Planning
- Project Management
- Microsoft Office
- CAD
- Robotics
- Tactical planning and execution
- Equipment maintenance and management
- Process optimization
- Project management
- Stakeholder engagement
- Team leadership
- Performance metrics
- Employee training
- Operational excellence
- Financial analysis
- Problem solving
- Change management
References
- Tom Heiman, Thumb Plastics, (517) 243-9514
- John Christian, S Group Automotive, (517) 404-9380
Timeline
MANAGEMENT CONSULTANT
Manufacturing Management Solutions
12.2019 - Current
OPERATIONS MANAGER
Thumb Plastics, Inc
09.2016 - 11.2019
PROJECT ENGINEER
S Group Automotive
06.2013 - 09.2016
PLANT OPERATIONS MANAGER
US Farathane
01.2012 - 06.2013
LEAN MANUFACTURING AND CONTINUOUS IMPROVEMENT MANAGER
Magna
01.2009 - 01.2012
BUSINESS UNIT MANAGER
Magna
03.2007 - 01.2012
SENIOR PROCESS ENGINEER
Magna
06.2002 - 03.2007
SENIOR PROCESS TECHNICIAN
Magna
10.1997 - 06.2002
MECHANIZED INFANTRY SQUAD LEADER
US Army
01.1990 - 02.1992
SPECIAL DUTY NUCLEAR SECURITY INFANTRY TEAM LEADER
US Army
08.1987 - 02.1990