Michael Berke
Justin,TX
Summary
Experienced and analytical Manufacturing Production Planner & Material Manager with a demonstrated track record of fine-tuning production processes, overseeing inventory management, and orchestrating logistics. Acknowledged for adept leadership in fostering collaboration and instigating productivity enhancements. Proficient in influencing sales and operations through a deep understanding of continuous improvement methodologies and daily workflows. Eager to apply analytical expertise in supply chain planning, SIOP, and Microsoft Excel as a Materials Planning & SIOP Specialist, striving to amplify efficiency and surpass customer expectations.
Overview
6
6
years of professional experience
1
1
Certification
Work History
Production Planner & Materials Manager
Rehrig Pacific Company (Plastic Injection Molding)
Dallas, TX
09.2021 - Current
- Develop and maintain injection plastic molding production schedules tailored to various manufacturing activities, ensuring alignment with current consumer demand (materials planning, SIOP).
- Utilize JDE Oracle Software to facilitate streamlined coordination across planning, development, manufacturing, and sales workflows.
- Provide environmental and supply chain sales teams with technical insights and product-specific information, empowering them to seize market opportunities (demand forecasts).
- Generate PowerBi SIOP reports that highlight analytical supply chain metrics, including lead times, yield rates, throughput, material usage, operational costs, waste rates, and productivity.
- Manage resource allocation and optimize inventory levels by analyzing material stocks, monitoring production performance, and overseeing backlogs (capacity planning, fulfillment demand).
- Oversee material management by leading a team towards exceeding company expectations.
- Negotiate subcontracts with plastic resin, colorant, and recycle vendors for better prices, terms, quality standards, delivery schedules.
- Built over 1,500 different Bill of Material's (BOM) in the past 2 years for plastic roll-out carts, beverage crates, bins, pails, trays, and pallets.
- Achieved just over 98.5% resin and raw material inventory accuracy for FY23 within the Dallas facility.
- Statistical forecasting and managing, on average, 2.8 million pounds of resin material per month.
- Earned 6 company Value Coins – Three Service, Two Growth, One Innovation
- Coordinate shipping and receiving activities to optimize warehouse inventory levels and minimize delays or back orders.
- Assist with new product development working side by side with marketing, sales, and project managers.
- Provide valued customers (ex. Pepsico, Coca-Cola, Amazon, Walmart, Waste Management) with accurate and detailed lead times daily.
- Managed 19 unique projects totaling 125,000 carts happening across the country over a 6-week span with multiple downtime events jeopardizing project deadlines.
Plant Production Supervisor
Rehrig Pacific Company (Plastic Injection Molding)
Dallas, TX
10.2020 - 09.2021
- Assigned responsibilities to team members and ensured precise task completion to achieve on time deliveries (OTD).
- Developed lean manufacturing process refinements, including a product changeover system that improved departmental quality, throughput, and minimized waste and operational downtime.
- Consistently steered a team to achieve optimal efficiencies across 12 major injection molding machines (capacity management).
- Oversaw equipment functionality, inventory levels, and manpower allocation to align with production demands.
- Created weekly work schedules to meet customer demands while optimizing labor costs.
- Implemented process improvements using lean methodology principles.
- Ensure sub-assemblies are produced and ready ahead of time while meeting quality standards.
- Developed a Microsoft Excel calculator using VBA and SQL used to document and improve OEE across all 7 Rehrig facilities.
- Assisted in setting up metrics and KPIs for tracking performance of the demand planning team.
- Lead on average of 10 plant tours per month to potential, existing, and internal customers while explaining Rehrig’s sustainability goals and practices.
Continuous Improvement Engineer
Centro, Inc (Plastic Rotational Molding)
North Liberty, IA
11.2019 - 10.2020
- Designed and manufactured industrial cooling fixtures for post cycle roto-molded parts (ex. John Deere hoods, Yeti Coolers, Kennels) to meet quality specifications.
- Designed blueprints using AutoCad for work cells, machine layouts, and other improvement builds.
- Coached cross-functional teams in the use of problem solving tools such as fishbone diagrams, Pareto charts, value stream maps, and other lean principals.
- Devised and implemented data-centric action blueprints, resulting in a monthly efficiency surge of over 20% in CNC machine operations, a yearly waste reduction of 15%.
- Built interactive dashboards using advanced formulas and functions within Excel, such as VLOOKUP, INDEX+MATCH, SUMIFS, COUNTIFS, and many more.
- Adopted and applied Lean Six Sigma techniques: Utilized the DMAIC (Define, Measure, Analyze, Improve, Control) framework to transformative projects.
- Achieved tangible outcomes encompassing cost reduction, quality enhancement, and accelerated cycle times.
- Worked closely with suppliers in order to evaluate their capabilities in meeting customer requirements.
- Facilitated stakeholder meetings to gain consensus on proposed changes or new initiatives related to continuous improvement efforts.
Wind Turbine Service Technician
Acciona Windpower
Ames, IA
07.2018 - 11.2019
- Inspected, maintained and repaired wind turbine components in accordance with safety procedures.
- Conducted routine checks on mechanical parts such as gears, brakes, bearings and blades.
- Troubleshoot technical issues using specialized diagnostic tools and equipment.
- Performed preventative maintenance on electrical systems including wiring, controls, sensors and generators.
- Responded quickly to emergency repairs when needed.
- Communicated effectively with supervisors regarding progress of tasks assigned.
- Analyzed blueprints and schematic diagrams to determine tools and parts needed to keep equipment operating at peak levels.
Education
Bachelor of Arts - Technology Management
University of Northern Iowa
Cedar Falls, IA05.2018
Associate of Applied Science - Energy Production And Distribution Technology
Kirkwood Community College
Cedar Rapids, IA05.2016
Skills
- Materials Planning: Demand Forecasting, Strategic Planning, Supply Chain
- SIOP: Forecast Analysis, Sales Strategy, Inventory, Ops Planning, Historical Data
- JD Edwards Software: BOM's, Parts List, PO/WO Creation, Item Data Management, Shop Floor Control, Inventory, Units of Measurement
- AutoCad: Electrical Diagrams, Machine/Work Cell Blueprints, Fixture Drawings
- Microsoft Office Suite: Excel Dashboard Creation, Pivot Tables, VBA, Advanced Formulas and Macros, Interactive Functions, Data Validation, Flow Charts, Reports
- Business Analysis: Cost-Benefit Analysis, KPI Tracking, New Product Development, Negotiation
- Continuous Improvement: Developing Metrics, Lean Manufacturing Principals, 5S, Value Stream Mapping, Waste Reduction, Statistical Process Control, Analytical
- Communication: Lead Team Meetings, PowerPoint Presentations, Lead Plant Tours
- Scheduling: Construct Daily Production Schedule, Organize Maintenance Plans, Facilitate Critical Product Relocation
- Positive Attitude
- Problem-Solving
- Conflict Management
- Leadership
- Analytical Thinking
- Team Collaborations
Certification
- Lean Six Sigma Green Belt Certification
- Value Engagement Sales Course
- Ongoing - Project Management PMP
Accomplishments
Six Rehrig Value Awards
Innovation Coin: Developed advanced spreadsheets utilizing Microsoft Excel and VBA Coding, enhancing reporting, documentation, and data recording processes for production, sales, and planning departments company wide.
Growth Coin: Demonstrated proficiency in assuming unforeseen responsibilities, including taking the initiative to lead a new team voluntarily.
Growth Coin: Exhibited adaptability in a new role and showcased persistence by consistently seeking clarifications through proactive questioning.
Service Coin: Upheld a positive demeanor daily and consistently exceeded expectations to cater to customer needs.
Service Coin: Stepped up by volunteering to oversee plant operations overnight during a power outage.
Service Coin: Embarked on a two-week journey to the California facility, imparting training to planners and streamlining their scheduling processes.
Timeline
Production Planner & Materials Manager
Rehrig Pacific Company (Plastic Injection Molding)
09.2021 - Current
Plant Production Supervisor
Rehrig Pacific Company (Plastic Injection Molding)
10.2020 - 09.2021
Continuous Improvement Engineer
Centro, Inc (Plastic Rotational Molding)
11.2019 - 10.2020
Wind Turbine Service Technician
Acciona Windpower
07.2018 - 11.2019
Bachelor of Arts - Technology Management
University of Northern Iowa
Associate of Applied Science - Energy Production And Distribution Technology
Kirkwood Community College
- Lean Six Sigma Green Belt Certification
- Value Engagement Sales Course
- Ongoing - Project Management PMP
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