Robert Hannigan
Clarksville,TN
Summary
Production coach and operations leader with 20+ years in manufacturing, continuous improvement, and workflow support. Delivered throughput gains by troubleshooting processing issues and improving daily execution. Strengthened retention through layout changes, structured training, and hands-on leadership.
Overview
27
27
years of professional experience
Work History
Lead Coach
Bridgestone Metalpha USA
Clarksville, Tennessee
05.2015 - Current
- Coached team members on problem solving and process discipline.
- Built team accountability through clear direction and consistent feedback.
- Mentored younger coaches by developing effective coaching techniques and strategies.
- Trained associates on safety, quality standards, and standard work practices.
- Tracked line performance and adjusted staffing to support smooth operations.
- Changed layout of ORR, increasing throughput from 3 tons to 19 tons per day.
- Implemented MSC process, coordinating launch needs and addressing Phase 1 setbacks to achieve improved outcomes in Phase 2.
- Redesigned layout over 4 years to integrate automation, reducing soft tissue injuries, cutting processing issues by 65%, enhancing team member retention, and fostering interdepartmental collaboration.
- Reviewed work instructions and ensured adherence to Metalpha procedures.
- Transitioned to WD area to address processing issues and provide guidance. to help support an area struggling with processing issues, manpower, and lack of direction
- Guided Bridgestone Metalpha USA production teams through daily workflow needs.
Process Support Coach
Bridgestone Metalpha USA
Clarksville, Tennessee
04.2012 - 05.2015
- Coached Bridgestone Metalpha USA team members on daily work standards, improving compliance and performance.
- Trained new associates on safety rules and job procedures.
- Documented attendance, concerns, and coaching discussions for management review.
- Coordinated schedule changes and coverage needs with plant leadership.
- Facilitated team meetings to ensure efficient communication between departments.
- Implemented new ORR process with machine setup and layout adjustments, reducing quality issues.
- Managed multiple projects simultaneously while ensuring timely completion of assigned tasks.
- Collaborated across departments to minimize downtime and enhance overall operational efficiency.
Team Leader / Coach
Bridgestone Metalpha USA
Clarksville, Tennessee
08.2007 - 04.2012
- Led shift production activities at Bridgestone Metalpha USA manufacturing operations.
- Coordinated team assignments to optimize daily workflow and schedules while collaborating with the Planning department to address issues and enhance operational efficiency.
- Promoted collaboration among team members by maintaining a positive work environment that encouraged open communication and teamwork.
- Trained new operators on work instructions and company standards.
- Monitored and enforced safety practices to ensure compliance with plant safety procedures and foster a culture of safety.
- Fostered a culture of continuous improvement, encouraging innovation and efficiency.
- Ensured smooth material flow to meet production targets and support departmental needs. to keep all departments on task to make production targets and customer needs.
- Communicated production issues with Maintenance, Quality, Technical, and Leadership.
- Reviewed product quality and reported defects to supervisors. Troubleshooting of machines to reduce processing issues and prevent future defective material
- Recorded shift activity details to maintain accurate operational logs for team transitions. and updated handoff notes for next team.
Team Member
Bridgestone Metalpha USA
Clarksville, Tennessee
10.2003 - 08.2007
- Supported Bridgestone Metalpha USA production line operations and material flow.
- Followed safety procedures and maintained clean work areas throughout shifts.
- Adapted to different roles to support the team's operational needs.
- Identified and implemented process improvements, enhancing departmental efficiency.
- Built and maintained working relationships with peers and upper management.
- Trained new team members using approved training materials and information.
- Proactively exceeded job requirements to advance team goals and foster collaboration. to go above and beyond job requirements. Helping others and learning new activities to support leadership
General Manager of Food Service
Fazoli's Restaurant
Smyrna, Tennessee
06.2001 - 10.2003
- Led daily restaurant operations at Fazoli's, supporting fast casual Italian service standards.
- Managed food quality, portion control, and kitchen procedures for consistent guest satisfaction.
- Supervised staff scheduling, shift coverage, and frontline team performance during busy service periods.
- Monitored inventory levels, placed supply orders, and controlled waste across food service areas.
- Resolved guest concerns and maintained positive service during dine-in, takeout, and drive-thru.
- Enforced sanitation, cleanliness, and health code standards throughout dining and kitchen spaces.
- Coordinated cash handling, daily reports, and opening and closing restaurant procedures.
- Scheduled staffing levels according to expected business volume on a daily basis.
- Ensured compliance with all local health codes, sanitation regulations, and company policies.
- Performed administrative tasks including payroll processing, budgeting activities.
- Started at Rivergate as 2nd Assistant, moved to Harding Place as 1st Assistant, and finished with General Manager at Smyrna
- Reduced food waste by overseeing and planning ingredients, anticipated customers, and popularity of items. Also, increased sales through promotion of catering services
Assistant Kitchen Manager
Shoney's Restaurant
Clarksville, Tennessee
09.1999 - 05.2001
- Supervised kitchen crew during Shoney's breakfast, buffet, and dinner service
- Monitored food safety, sanitation, and health code compliance
- Checked inventory levels and ordered ingredients for kitchen use
- Coordinated daily food preparation and kitchen workflow
- Supported scheduling, shift coverage, and closing procedures
- Organized inventory and placed orders for food, equipment, and supplies to maintain appropriate stock levels.
- Created weekly schedules according to business demands while ensuring labor costs remained within budget parameters.
- Chosen to be part of a traveling team called the A-Team. Traveled to different locations to help increase sales by reducing variation, promote quality standards, and train proper techniques to maintain food quality
Education
High School Diploma -
Northeast High School
Clarksville, TN08-1999
Skills
- Team coaching
- Production scheduling
- Quality control
- Continuous improvement
- Data analysis tools
- Microsoft Office expertise
- Leadership skills and motivation
- Motivational skills
- Collaborative approach
- Clear communication
- Collaborative approach
- Leadership style
Accomplishments
- TQM award, 2019
- Shoney's Traveling A-Team
Timeline
Lead Coach
Bridgestone Metalpha USA
05.2015 - Current
Process Support Coach
Bridgestone Metalpha USA
04.2012 - 05.2015
Team Leader / Coach
Bridgestone Metalpha USA
08.2007 - 04.2012
Team Member
Bridgestone Metalpha USA
10.2003 - 08.2007
General Manager of Food Service
Fazoli's Restaurant
06.2001 - 10.2003
Assistant Kitchen Manager
Shoney's Restaurant
09.1999 - 05.2001
High School Diploma -
Northeast High School