Summary
Overview
Work History
Education
Skills
Affiliations
Timeline
Volunteer
Michael W. Kosta

Michael W. Kosta

President/GM Manufacturing
Mission Viejo,CA

Summary

General Manager/President – Manufacturing Strategic Leadership - Turnaround Management - Efficiency - Kaizen - Lean Manufacturing High performance, results driven senior executive with a solid career history of demonstrating visionary leadership and expertise in business start-ups, turn around, and operational management of single and multi-site manufacturing facilities. Strong P&L track records with functional management expertise in all disciplines of manufacturing operations. A catalyst for change, combining tactical execution of strategic initiatives with strong leadership of cross functional staff and development of key alliances to capture and enhance overall quality, productivity and bottom-line financial performances. Career Highlights 42 years in world-class manufacturing leadership. Areas include, quality(ISO&AS9100), inventory, project management, profit management, sales, marketing and customer service. Development of strong lean thinking management teams. Development of strong safety programs resulting in low to no lost time accidents and very low workers compensation premiums. Cut OSHA recordable accidents by 86.7% as an average in all facilities. Implementation of strong quality programs including ISO registration. Elimination of departmental barriers to allow for quick and decisive directional changes and program implementations Kaizen used as continuous improvement vehicle. Development of strong ERP, MRP business systems resulting in 99.90% bill of material accuracy, inventory accuracy, scheduling, forecasting, costing and shop floor control. Kanban techniques used as a tool in some of the facilities. Cutting cash conversion cycles by decreasing facility lead-times through the implementation of vendor managed inventories, work cells, line balancing and waste elimination. Growing two companies top lines while improving the bottom lines. Area of Expertise Leadership Team Development Plant Expansion/Consolidation MRP/ERP Implementation New Product Development Continuous Process Improvement Cost Reduction Initiatives ISO Plant Certifications Lead-time Reductions Process Waste Removal Employee Involvement Programs Financial Management P&L Lean & Kaizen Work Cells 5S Methodology Flooring Programs (Consignment) Versatile business leader bringing Number years of experience as accomplished Job Title. Strategic problem-solver, change manager and visionary executive with success implementing plans to meet current and future needs. Key expertise in Industry. Results-oriented Industry executive with demonstrated record of accomplishment in streamlining operations, increasing profits and maximizing market penetration. Decisive leader promoting operational improvements, market expansion and positive corporate culture as keys to success. Talented President with excellent employee development, customer service and analytics skills coupled with more than Number years of experience. Comfortable giving engaging presentations to clients to drive new business, expand accounts and establish brand profile. Excellent team builder and leader of initiatives. Persistent leader eager to lead and grow organizations. Skilled in strategic planning, problem-solving, and communication with good understanding of business principles, project management and team leadership. Collaborative with relentless work ethic. Pragmatic professional with solid experience in leadership roles. Adept at implementing strategic business plans, driving growth and improving operations. Skilled in financial management and stakeholder relations. Collaborative and dedicated to building and leading talented and motivated individuals. Top-notch Job Title with proven track record of success leading and growing organizations. Strong background in strategic planning, financial management and team development. Skilled in identifying opportunities and implementing practical business strategies with commitment to staying informed about latest trends, technologies and best practices.

Overview

40
40
years of professional experience

Work History

President

HANMAR CORP
01.2019 - 01.2020
  • Multi-facility, full service, Aerospace spinning and draw forming
  • OEM sheet-metal & machine shop manufacturing company, specializing in electro-mechanical assemblies and equipment
  • Aerospace fabrication, Provided overall leadership for all operational departments and facilities
  • Implemented cellular manufacturing in the plant
  • Set up twelve stand-alone cells
  • Improved overall productivity, while decreasing labor 16%
  • Implemented 5S and other “Lean” technologies focused on elimination of waste
  • Developed direct cell management leadership, placing accountability at the floor level.

General Manager

FABCON, INC
01.2009 - 01.2018
  • Multi-facility, full service, OEM sheet-metal & machine shop manufacturing company, specializing in electro-mechanical assemblies and equipment
  • Aerospace fabrication, Provided overall leadership for all operational departments and facilities
  • Tripled overall size of the company, fasted growing awards 3 years in Orange County,
  • Implemented cellular manufacturing in the plant
  • Set up twelve stand-alone cells
  • Improved overall productivity, while decreasing labor 16%
  • Implemented 5S and other “Lean” technologies focused on elimination of waste
  • Developed direct cell management leadership, placing accountability at the floor level.

Director of Manufacturing

ACCURATE METAL FABRICATORS INC
01.2008 - 01.2009
  • Multi-facility, full service, OEM sheet-metal & machine shop manufacturing company, specializing in electro-mechanical assemblies and equipment
  • ($100MM annually), Provided overall leadership for all operational departments and facilities
  • Consolidated two manufacturing facilities into one site
  • Implemented cellular manufacturing in the plant
  • Set up twelve stand-alone cells
  • Improved overall productivity, while decreasing labor 16%
  • Implemented 5S and other “Lean” technologies focused on elimination of waste
  • Developed direct cell management leadership, placing accountability at the floor level.

General Manager

EASTER-OWENS
01.2007 - 01.2008
  • Service manufacturing facility specializing in NEMA enclosures with full electrical integration including PLC programming
  • Provided overall leadership for all departments and full P&L responsibility
  • Implemented ISO 9001:2000 in five months to secure needed business
  • Certified by SARA registrar
  • Re-organized the leadership team for continuous manufacturing methods vs
  • Batch methods
  • Improved customer quality rating from 92% to 99%
  • Improved on-time shipments from 60% to 95%
  • Decreased inventory by 25% while increasing sales by 22% over a one-year period
  • Improve net profits by 11%.

General Manager/VP of Operations

SYNERGY MANUFACTURING
01.2003 - 01.2007
  • Multi-facility, full service, OEM sheet-metal & machine shop manufacturing company, specializing in electro-mechanical assemblies and equipment
  • Provided overall leadership for all departments and full P&L responsibility
  • Challenged to create a plan that would consolidate four manufacturing facilities into one larger full-service manufacturing company
  • Consolidation completed in six months
  • 95% improvement in overall lead-time
  • Implemented Vantage RP software (Epicor)
  • Worked company out of Chapter 11 with little or no working capital
  • Cut lost time accidents by 78% while drastically reducing OSHA recordable accidents
  • Successfully orchestrated the sale of the company.

President/General Manager

ENGINEERED DATA PRODUCTS, INC
01.2001 - 01.2003
  • A world-class manufacturer of high-density computer workstations, enclosures, command consoles, media storage racks and telecommunication (data room) infrastructure
  • Provided overall leadership for all departments and full P&L responsibility
  • Implemented ISO 9001:2000
  • Certified by ORION registrar
  • Challenged with the objective to right size a company operating as a $46M company with sales volumes of $27M
  • Cut all unnecessary costs within first two months to create a positive cash flow
  • Implemented a Manufacturer Sales Representative model to replace costly Direct Sales Force
  • Re-implemented JD Edwards RP software in six months resulting in a fully functioning MRP program
  • Converted business from a four to six-week lead-time to a three-day quick ship and two-week standard lead-time model
  • Accomplished this through major waste reduction initiatives, work cells and many front office Kaizen events
  • Improve cash conversion cycle by implementing consignment programs on direct material items
  • Spear headed the complete telecom product line in six months with estimated annual sales of 3M.

General Manager / VP of Operations

COOPER B-LINE INC
01.1994 - 01.2001
  • 30M Manufacturer of telecommunication (data room) infrastructures & OEM sheet-metal & machine shop
  • Provided overall leadership for all departments
  • General Manager of one of seven full-service manufacturing facilities throughout the US
  • Cooper B-Line’s only make to order facility
  • All other facilities were producing to stock and shopping from stock
  • Successfully managed and implemented waste reduction initiatives to improve bottom line profits at a rate 15%/year
  • Doubled company size while only increasing direct labor by 9% by using Kaizen and Lean Manufacturing techniques
  • Implemented ISO 9001:2000
  • Certified by ORION registrar.

General Manager / VP of Operations

DAW TECHNOLOGIES INC
01.1993 - 01.1994
  • Manufacturer of complete clean rooms and air handler equipment & OEM sheet-metal & machine shop
  • Provided overall leadership for all departments
  • Challenged to overcome morale and productivity issues, resulting in the re-structuring of the direct workforce and eliminating the use of long-term temporary employees
  • Improve on-time shipment from 70% to 95%
  • Improved customer quality rating from 85% to 93%.

Plant Superintendent

NATTER MANUFACTURING INC
01.1980 - 01.1993
  • 45M full service OEM sheet-metal & machine shop manufacturing company
  • Started in production with promotions to Manufacturing Supervisor, Materials Manager and finally Plant Superintendent
  • First sheet metal manufacturer in North America to receive ISO 9000 certification
  • Four years without lost time accident, equaling to 1 million man-hours
  • 86% reduction in OSHA recordable with major emphasis on safety.

Education

M.R.P - undefined

Salt Lake Community College

Skills

  • Creating and Delivering Presentations
  • Inspirational Leadership
  • Remote Team Management
  • Revenue Operations
  • Develop Business Structures
  • Capital and Resource Management
  • Mission and Vision
  • Employee Motivation and Performance
  • Project Oversight
  • Strategic Partnership
  • Articulate Communication
  • Lean Methodology
  • Approachable and Outgoing
  • P&L Responsibility
  • Innovative and Visionary
  • Business Administration
  • Deployment Management
  • Budgeting and Cost Control
  • Organizational Leadership
  • Vendor Sourcing and Negotiations
  • Industry Expertise
  • Contract Negotiation
  • Quality Control Planning
  • Profit Growth Strategies
  • Leadership and People Development
  • Financial Planning
  • Expectation Management
  • Defining Company Vision
  • Analytical and Critical Thinker
  • Budget Management
  • Build Revenue Streams
  • Executive Performance Management
  • Staff Training
  • Business Development
  • Operational Excellence
  • Operations Management
  • Management Team Leadership
  • Strategic Planning
  • Program Oversight
  • Capital Expenditure Planning
  • Professional Integrity
  • Results Orientation
  • Strategize Plans
  • Corporate Strategy and Development
  • People and Culture
  • Departmental Coordination
  • Adaptable and Flexible
  • Change and Growth Management

Affiliations

Society of Manufacturing Engineers (SME) – American Society for Quality (ASQ)

Timeline

President

HANMAR CORP
01.2019 - 01.2020

General Manager

FABCON, INC
01.2009 - 01.2018

Director of Manufacturing

ACCURATE METAL FABRICATORS INC
01.2008 - 01.2009

General Manager

EASTER-OWENS
01.2007 - 01.2008

General Manager/VP of Operations

SYNERGY MANUFACTURING
01.2003 - 01.2007

President/General Manager

ENGINEERED DATA PRODUCTS, INC
01.2001 - 01.2003

General Manager / VP of Operations

COOPER B-LINE INC
01.1994 - 01.2001

General Manager / VP of Operations

DAW TECHNOLOGIES INC
01.1993 - 01.1994

Plant Superintendent

NATTER MANUFACTURING INC
01.1980 - 01.1993

M.R.P - undefined

Salt Lake Community College
Michael W. KostaPresident/GM Manufacturing