Summary
Overview
Work History
Education
Skills
Timeline
Generic

Matthew Watts

Dunellen,NJ

Summary

I am a results driven and dedicated person with wide-ranging experience in the fields of both manufacturing and management, accomplished in team building and problem solving. I have experience with lean manufacturing and continuous improvement. I have 24 years of manufacturing experience in custom and profile extrusion, thermoforming, and injection molding. Within those years I acquired 10 years of experience in supervision and 5 years of plant management of personnel ranging from 10- 80 direct and indirect reports, material handling, inventory management, new process validation and standardization, and extensive polymer experience.

Overview

26
26
years of professional experience

Work History

Senior R&D Engineer

TFH Nylabone
09.2023 - Current
  • Reporting to the VP of Research and Development- developed training modules for operations of molding, extrusion, sanitation, and packaging departments in order to

Plant Manager

TFH Nylabone
01.2018 - 09.2023
  • Manage the day-to-day operations of two manufacturing facilities consisting of (62 750 ton IMM/ 3 twin screw extruders, one capable of 5 ton/ hr. other two capable of 4 ton/ hr. of edible product)
  • Participated as a point person for extrusion Bulk batching system for extrusion process that reduced head count in the department by half and increased outputs more than 30% year to year
  • Develop and execute work instructions and SOPs concerning all departments associated with production/ inventory management/ sanitation
  • Work closely with VP of operations to ensure production goals are achieved on time and in a physical and food safe manner
  • Organize and oversee weekly Production/ scheduling/ inventory/ maintenance meeting to keep lines of communication open between departments and facilitate necessary production demands by ensuring inventory of raw materials are available to meet scheduled demands
  • Participate in daily weekly S&OP meetings to examine and anticipate customer schedules/ forecasting and prepare production to meet the needs of the customer
  • Attend and contribute to weekly Marketing meetings
  • Work very closely with R&D in development of formula for both edible and non-edible products
  • Work closely with and advise process engineers in material and mold/ extrusion sampling
  • Conceive and develop standardized processes for both Extrusion and Molding departments
  • Develop training manuals based on equipment and processes to include both physical and food safety to ensure best practices of operation
  • Conduct daily plant walk throughs to ensure house keeping and Sanitation goals are met, and plant is always audit ready
  • Conduct MRB meetings daily to review “on hold” or rework product in order to recognize defects and establish “root cause” and add findings to developed production packets so supervision/ technicians/ and machine tenders can recognize and resolve issues at the machine level
  • Hold monthly employee shift meetings to discuss “state of the business” and the implementation of new work instructions or company policies
  • Track labor costs through spread sheets that calculate cost of machine run rates/ machine downtime/ scrap rate/ develop and maintain KPIs related to Safety Quality Delivery Engagement and Productivity along with Pareto charts both statistic and living

Production Manager

TFH Nylabone
01.2012 - 01.2018
  • Manage extrusion/ pelletizing department consisting of: (2) Twin screw extruders for 24 hour production of edible bead and extruded edible bones- two direct reports supervisors/ two extruder technicians, four mixing, and batching persons.
  • Developed system to pre heat dies and tool carts with shadow boards and necessary “quick change over” tools working towards “Single Minute Exchange of Dies” reduced down time and non-value added movement during change overs
  • Developed efficient layout of downstream extrusion equipment to further reduce downtime and movement of equipment and personnel.
  • Management of injection molding department consisting of: 25 700 ton injection molding machines for 24- hour 7- day- a- week production of both edible and plastic dog bones and dog treats.
  • Managed Direct reports consisting of a total of two production supervisors/ eight molding technicians.
  • Managed additional 80 indirect production personnel.
  • Performed mid- year and end of year performance reviews for direct reports
  • Reviewed indirect report personnel performance reviews and coached supervisors on performing mid- year and end of year reviews
  • Performed first level interviews for all perspective production employee candidates
  • Developed the use of visual aids and “on the line” work instructions, that included visual quality aids to reduce defects and ensure all machine operators, regular or temporary, understand process of standard work practices and PPEs needed to perform job(s)- production packets
  • Investigated and worked with engineering and high level management to implement the purchase of gravimetric blenders and plastic material handling system that deliver polymers directly to injection molding machines. The addition of these systems reduced staffing of three plastic material handling positions to one per shift. Material waste savings of $250,000 to $300,000 yearly.
  • Reduced inventory of regrind from 500,000lbs. to under 65,000lbs. through implementing and training molding technicians and supervisors in 100% recycled materials usage processing program
  • Developed production cells with the development of “production assistant” position. This position consisted of 4 employees per shift whose objective is to load edible material for four edible injection molding machines utilizing hot runner systems allowing one operator to run two to three machines. This action contributed to reduction of overall head count per shift from 46 direct and indirect to 34 employees and reducing temporary labor in half for both shifts
  • Developed strict job accountability descriptions for all production employees from production manager position to machine tenders and sanitation personnel.
  • Supervising staff, auditing team production, communicating job expectations, and organizing department to ensure quality turnaround time and efficiency.

Production Supervisor

TFH Nylabone
01.2011 - 01.2012
  • Responsible for filling out all production controlled documentation
  • Responsible for ensuring all floor personnel on the day shift (35-40 direct reports) observe all physical and food safety guidelines cGMPs and utilized all necessary PPEs.
  • Participated in and lead GEMBA walks to review KPIs on a daily basis in order to review indicators related to Safety/ Quality/ Delivery/ Cost/ Engagement. Utilized pareto charts to compile weekly/ monthly data associated with each of the Indicators.
  • Developed processes to eliminate non- value added work in the edible treat production from extrusion to molding “moisture controlled bead” project
  • Conducted weekly staff meetings to explain goals for production and addressing employee concerns and anticipated pitfalls to achieving set production goals
  • Maintained safe and clean work environment by educating and directing team on the use of equipment, tools and resources.
  • Participated in companywide move towards “Operational Excellence” with the introduction of lean manufacturing
  • Directly participated in 4 kiazen events designed to standardize work flow in extrusion and molding areas of our facility
  • Attended and completed one week kiazen leaders class in order to begin the “green belt” process
  • Assisted others in the development and completion their “Green Belt” projects
  • Continued to work with continuous improvement team until company turned away from lean values. Continued to apply values and lean mind set wherever and whenever permitted.

Night Shift Extruder Technician (Lead Position)

TFH Nylabone
01.2009 - 01.2012
  • Responsible for the operation of (2) twin screw extruders in the production of edible pellets to be utilized in the injection molding process in the manufacturing of edible dog treats
  • Supervised direct reports consisting of one assistant extruder technician and four mixing and batching personnel
  • Filled in for injection molding Supervision when needed in the process learned injection molding processing and troubleshooting, furthered supervision and management skills

Supervisor Plastiglide Division

ITW Thielex
01.2006 - 01.2009
  • Supervised 10 direct reports
  • Scheduled production and material purchasing
  • Employee coaching, training, and evaluation
  • Developed extrusion process to utilize 100% regrind to produce quality products
  • Purchased regrind from other sources to reprocess and produce quality products tremendous cost savings
  • Streamlined custom open profile extrusion process utilizing 5S, work standardization, and installation of die heating stations in order to reduce change over and machine down time by 30% (SMED).
  • Attended lean manufacturing program through IKP Logistics provided to company through New Jersey Lean manufacturing grant

Set up/ Machine Operator - Extrusion - Thermoforming

ITW Thielex
01.1999 - 01.2006
  • Set up tools and dies for extrusion and thermoforming
  • Gained experience with many different polymers- ridged and soft durometer PVC/ ABS/ HIPS, nylons, PETG, polypropylene, polyethylene, polycarbonate, butyrate, and polymer booster and foaming agents.
  • Attended several Skill Path supervisor/ management courses

Education

Kiazen Leader Course -

Central Garden and Pet OPEX
01.2013

Credits toward Degree - Education/History Major

Brookdale Community College
01.2009

Commercial Art/Graphic Design Certificate -

SCTI
01.1993

Graduate -

Dunellen High School
01.1991

Skills

  • Training and mentoring
  • Team leadership
  • Supply chain optimization
  • Quality management systems

Timeline

Senior R&D Engineer

TFH Nylabone
09.2023 - Current

Plant Manager

TFH Nylabone
01.2018 - 09.2023

Production Manager

TFH Nylabone
01.2012 - 01.2018

Production Supervisor

TFH Nylabone
01.2011 - 01.2012

Night Shift Extruder Technician (Lead Position)

TFH Nylabone
01.2009 - 01.2012

Supervisor Plastiglide Division

ITW Thielex
01.2006 - 01.2009

Set up/ Machine Operator - Extrusion - Thermoforming

ITW Thielex
01.1999 - 01.2006

Credits toward Degree - Education/History Major

Brookdale Community College

Commercial Art/Graphic Design Certificate -

SCTI

Graduate -

Dunellen High School

Kiazen Leader Course -

Central Garden and Pet OPEX

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