Michael Shull
York,PA
Summary
Production management professional with extensive experience in manufacturing, specializing in strategic planning and operational excellence. Proven track record in enhancing safety protocols and achieving Key Performance Indicators through Lean manufacturing practices. Strong analytical skills utilized to streamline operations and foster team development.
Overview
1
1
Certification
26
26
years of professional experience
Work History
Production Manager
Graham Architectural Products (Oldcastle Building Envelope)
York, PA
07.2024 - Current
- Reporting to the Operations Director, directs a group of 8 supervisors with an hourly base of 82 associates. Currently managing a variety of departments from metal fabrication through assembly of finished goods. Over the two plus years of tenure have become an integral part of the improvement of the facility's Key Performance Indicators (KPI)within our Toyota Production Systems (TPS) activities. Key contributor of scheduling and production planning to match current backlog of jobs within the system and assisting in the improvement of On Time and In Full (OTIF) to our final customer.
- Provides a progressive safety forward approach with all associates. Contributes to incident investigations that resolve and reduce the chances of reoccurrence.
- Designed and developed the "Leadership Development Program". Modeled around the 5 Practices of Exemplary Leadership. Deployed to all supervisors for completion to enhance leadership skillsets.
- Instituted accountability for first article inspections in CNC and machining, reducing non-conformance of large batch errors.
- Consistently provides training and TPS mindset with supervisors and leads to solving issues and asking for assistance when in need.
- Organized monthly "Brown Bag Luncheons" to collect feedback from hourly associates on workplace issues, fostering open communication and engagement.
- Daily L4 walks to all departments, Genba each day through assembly, and champion of the organization's L4 Responsiveness KPI.
- Since 1976 Graham Architectural Products has been an industry-leading architect's supplier of custom commercial windows, doors and window wall products for historical and new projects throughout the United States and the world.
Operations - Area Manager, Finishing Mill
Cleveland Cliffs
Steelton, PA
01.2022 - 01.2023
- Reported to Plant Manager. Oversaw Finishing and Shipping of rail and semi-finished products, managing 70 employees in a union environment with a $3M budget. Provided production direction, reporting, and corrective actions on safety issues.
- Spearheaded plant turnaround of an unprofitability production plant to profitable by reducing operational and maintenance costs by 30%. Motivated team to meet and exceed KPIs and focused on production efficiencies, continuous improvement, and further cost reduction strategies.
- Met Business Plan financial EBITDA and KPI goals – Plant-wide EBITDA to exceed 1.5M monthly. Key Performance indicators to include safety, quality, and various productivity metrics.
- Ensured adherence to Rail Finishing's Safety Plan to promote a safe working environment. Engage associates in Safety initiatives and corrective actions to reduce incidents through incident and near miss reporting.
- Developed and implemented training initiatives for associates to achieve compliance with ISO 9001/14001/45001 and AAR certifications.
- Meet mill utilization goals for Rail and Semi-Finished products through increased efficiency, hours and added shifts of production.
- Oversaw quality assurance for semi-finished and rail products to meet strict internal and external customer specifications. Audited and modified quality procedures for accurate testing and measurement of products.
- Develop, monitor and prepare Rail Finishing Monthly Performance and Cost Review corporate communications.
- An integrated steel operation with carbon steel melting, casting, hot- and cold-rolling, and finishing operations with total revenue of $21B.
Production Supervisor
Church and Dwight Inc. (Arm and Hammer)
York, PA
01.2009 - 01.2022
- Coordinated all operations in a liquid bottling (5 Lines) and granulated (2 Lines) packaging manufacturing facility. Led a team of 60 operations associates of multiple disciplines. Departmental yearly budget of $3.5M
- Drove daily (Gemba) and long-term Lean Manufacturing initiatives, resulting in cross-departmental collaboration among engineering, production, quality, maintenance, and shipping teams to implement daily directives and improve line performance.
- Achieved $300K in annual savings by reducing line changeover time from 4 hours to 1.5 hours.
- SMED Event – Filling Line 4 Changeover time Reduction – 3 days – 12 associates
- Create changeover carts in order to stage tooling while in production.
- Develop conveyor railing limit notches to match bottle sizes – reducing changeover time.
- Reduce changeover time through quick change tool-less tooling changes and line adjustments.
- Drove total quality management to ensure customer satisfaction. Modified quality paperwork to resolve corrective actions from quality incidents.
- Yearly savings of $400K waste reduction + Safer working environment
- Established program for handling and storing reclaim totes, improving operational efficiency and reducing waste.
- Work with Quality Assurance to create avenues of reclaim into product stream to reduce waste.
- Advanced continuous improvement. PDCA, Kaizen events, SMED events, "Mantec" Lean Manufacturing Certified, progressive 5S.
- Led 4-day Kaizen event in compounding area, engaging 15 associates for process improvement
- An American consumer goods company focusing on personal care, household products, and specialty products with total revenue of $5B.
Decoration Process Engineer
Graham Packaging Inc.
York, PA
01.2007 - 01.2009
- Graham Packaging Company, founded in 1970 and headquartered in Lancaster, Pennsylvania, designs, manufactures, and sells customized blow-molded plastic containers. Total revenue of $1.4B
- Managed corporate projects focused on process improvements in high-speed screen printing of personal care bottles, enhancing production efficiency.
- Executed a high-speed vision quality system integrated with machinery to improve product quality and efficiency.
- Created a high-speed leak detection system integrated with machinery to ensure product integrity and reduce waste.
- Developed comprehensive rebuild procedures for screen printing machines, streamlining maintenance and optimizing operations.
Production Supervisor (Blow Molding Facility)
Graham Packaging Inc.
York, PA
01.2003 - 01.2007
- Coordinated labor and material production scheduling for 13 lines in bottle molding facility, overseeing 40+ team members to ensure efficient workflow.
- Graham Packaging Company, founded in 1970 and headquartered in Lancaster, Pennsylvania, designs, manufactures, and sells customized blow-molded plastic containers. Total revenue of $1.4B
Production Supervisor (Recycling Facility)
Graham Packaging Inc.
York, PA
01.2001 - 01.2003
- Supervise labor, raw materials and finished goods production in a (3 lines) HDPE PCR (Post-Consumer Regrind) facility with a group of 20+ team members.
- Graham Packaging Company, founded in 1970 and headquartered in Lancaster, Pennsylvania, designs, manufactures, and sells customized blow-molded plastic containers. Total revenue of $1.4B
Education
Bachelor of Business Administration (BBA) - Organizational Leadership
Southern New Hampshire University
Manchester, NH01-2020
Associate of Arts (AA) - Commercial Art and Visual Communications
Bradley Academy for the Visual Arts
York, PA01-1990
Skills
- Production Management
- Supply Chain Management
- Inventory Management
- Production Scheduling
- Cost Reduction Strategies
- Lean Manufacturing / 5S
- Continuous Improvement
- Process optimization
- Quality Assurance / Safety
- ISO certifications
- Strategic Planning / Execution
- Root-Cause Analysis
- Collaborative Leadership
- Team Development
- Problem-solving
Personal Information
Title: GENERAL MANAGER PRODUCTION MANAGER PLANT MANGER
Certification
Introduction and training of “Check Six” Methodologies – “Commander’s Intent” and “Associate to Associate” buy in., Leadership Development Program (Cleveland-Cliffs), 2022, Lean Operations Certified (Mantec) “Winning Teams”, 2020, PA Health Insurance Licensed, 2009, ServSafe, 2008
Timeline
Production Manager
Graham Architectural Products (Oldcastle Building Envelope)
07.2024 - Current
Operations - Area Manager, Finishing Mill
Cleveland Cliffs
01.2022 - 01.2023
Production Supervisor
Church and Dwight Inc. (Arm and Hammer)
01.2009 - 01.2022
Decoration Process Engineer
Graham Packaging Inc.
01.2007 - 01.2009
Production Supervisor (Blow Molding Facility)
Graham Packaging Inc.
01.2003 - 01.2007
Production Supervisor (Recycling Facility)
Graham Packaging Inc.
01.2001 - 01.2003
Bachelor of Business Administration (BBA) - Organizational Leadership
Southern New Hampshire University
Associate of Arts (AA) - Commercial Art and Visual Communications
Bradley Academy for the Visual Arts