Rod Lewis
Renton,WA
Summary
Manufacturing professional with a proven ability to optimize production workflows and implement operational improvements. Known for reliability and a strong commitment to collaborative teamwork, consistently achieving measurable results. Demonstrated expertise in process optimization and strategic planning, adapting to meet the ever-changing demands of the industry. Experienced in managing both unionized and non-unionized plants, ensuring smooth operations and fostering positive employee relations.
Overview
30
30
years of professional experience
Work History
Director of Manufacturing
Cascade Coffee
11.2023 - Current
- Improve overall Safety Culture and KPIs by creating a Strategic Masterplan for Safety
- Improved T.I.R.R
- From 8.0 to 4.11
- Improved morale on the floor by making a connection with the team and made sure everyone felt heard
- Increased weekly coffee output from 100,000 to 170,000 pounds per week
- The improvements were driven by creating a Strategic Plan with my team
- Managed Co-Packer customer relationships with customers like Starbucks, Nestle, Pete’s and Death Wish Coffee
- Reporting to COO
- Responsible for strategic leadership for Manufacturing, Maintenance, Engineering, Packaging and Sanitation
- Created a Plant Leadership Team and standardized meeting agenda
- Responsible for developing and meeting financial goals for all departments
- Responsible for creating annual Capital Budgets and project list
- Successfully rolled out the use of Autonomous Maintenance Tools such as Defects and Centerlines to the floor
- Implemented changes to the labor plan that resulted in a 25% labor reduction by taking the plant to a 4x10 schedule format and teaching managers how to manage their labor
- Revised the PM systems so it would work effectively and used interns to create a Critical Spare Parts list
Plant Manager
National Beverage Corp.
07.2019 - 11.2023
- Responsible for the daily leadership of multiple sites
- One plant and two distribution centers
- Responsible for the daily oversite and leadership of Scheduling, HR, Admin, Shipping, Warehouse Ops, Supply Chain, Maintenance, Engineering, QA and Manufacturing of top Sparkling Water brand
- Created a Plant Leadership Team and standardized meeting agenda
- Responsible for developing and meeting financial goals for all departments
- Responsible for creating annual Capital Budgets and project list
- Successfully negotiated current C.B.A with Teamsters Loc.#117 and #174
- Experienced facilitating all levels of the union grievance process
- Comfortable meeting with Senior Level Executives such as CEO’s, VP’s and Director’s
- Successfully implemented some of the Autonomous Maintenance tools to reduce downtime by 20%
- Established a critical spares program drastically reducing Major Breakdowns
- Led the plant through the planning, installation, and start-up of a new high speed fully automated can line
- Led a cost savings project focused on the reduction of water usage that reduced cost by 25% or annualized saving of $810,000
- Responsible for creating and executing the Strategic Plan
- Reduced OSHA Recordable from 10 per to one per year
- Developed and managed Zero Based operating budgets for QA, HR, Maintenance, Manufacturing, Logistics and Sanitation
- Managed and developed eight Salaried Managers and responsible for an overall plant population of 150 employees
- Responsible for Facilitating Monthly Plant Communications Meeting
- Implemented Root-Cause Analysis process for the plant, which reduced reoccurring breakdowns
- Lead the Plant thought the 1st SQF Certification
Operations Manager
JM Smucker Co. (Formally Sahale Snacks)
11.2017 - 07.2019
- Responsible for establishing and driving attainment of KPI’s
- Developed and managed operations budgets for QA, Maintenance, Manufacturing, Logistics and Sanitation
- Managed and developed 4 Salaried Managers and an employee population of 150
- Led key capital projects and CQVs which reduced cost and improved efficiencies
- Developed Strategic Master Plans for QA, Maintenance, Manufacturing, Logistics and Sanitation
- Drove actions needed to achieve high 3rd party audit scores
- Lead Operations teams to achieve a Zero Recordable Accident and .72 Total Incident score
- Directed all facility maintenance activities to ensure the safe production of food
- Responsible for creating processes for ensuring on-going compliance with FSMA
- SQMS Pillar Leader responsible for the leadership and deployment of Autonomous Maintenance tools
- Directed and maintained all facility management systems needed to ensure the safe and optimally functioning systems in a distribution and food processing operation
- Responsible for the creation of the DDS Meeting and its content to address any operational performance gaps
- Developed and led the creation and deployment of the Plant Food Defense Program
Director of Manufacturing
Sahale Snacks
11.2015 - 11.2017
- Member of the plant Executive Leadership Team
- Directed and managed all activities for Production, Maintenance, Safety and Sanitation for the company
- Responsible for managing $35 Million operating budget
- Successfully managed numerous Capital Projects at different levels of complexity
- Developed the strategic vision and objectives for Manufacturing, QA, Sanitation and Maintenance
- Plant manufacturing processes were awarded 'Manufacturer of the Year' Seattle Business Magazine
- Developed metrics that established standards for yield performance run efficiencies, cleaning, downtime, and unplanned stops standards
- Developed labor models to support the improvement of profitability
- Established systems for the implementation of FSMA requirements
- Established Sanitation best practices to support Food Adulteration Prevention requirements
Plant Manager
Sahale Snacks
12.2010 - 11.2015
- Managed six direct reports including salary and hourly employees
- Led teams to meet or exceed KPI’s year over year
- Reduced the number of recordable injuries by 75%
- Developed and implemented a Pay and Progression system to allow employees to be paid for obtaining skills to support business objectives
- Responsible for developing HACCP systems and processes
Plant Manager
Green Garden Foods
09.2008 - 12.2010
- Responsible for the daily oversite and leadership of Scheduling, Shipping, Warehouse Ops, Supply Chain, Maintenance, Engineering, QA and Manufacturing of bottled ready to eat products
- Reported directly to the owners of the company
- Led the plant transition towards the use of automation in half of the production areas
- Manage 6 direct reports and 100 indirect reports
- Developed systems and SOPs to ensure predictable and repeatable results
Operations Manager
Pathway Medical Technologies
05.2005 - 09.2008
- Oversaw the day-to-day operations for the manufacturing and shipping of FDA approved medical devices
- Successfully navigated my team though the challenges of a startup company
- Used Six Sigma to find and eliminate waste
- Led all activities in a clean room environment
Operations Manager
Campbell Soup Co.
07.1997 - 05.2005
- Oversaw the day-to-day operations for processes and procedures needed to produce fresh refrigerated soups
- Successfully relocated all manufacturing processes and systems to a new plant
- Used Lean concepts to redesign processing areas resulting in a reduction of waste
- Responsible for plant safety and the implementation of the 'STOP' for Safety program
- Successfully led projects that reduced processing times by 25%
- Managed and directed 3 direct reports and 50 production employees
Production Manager
Genie Industries
07.1994 - 07.1997
- Oversaw the day-to-day operations for processes and procedures needed to manufacture Articulating Boom lifts
- Responsible for labor and KPI
- Used Lean concepts to redesign processing areas resulting in a reduction of down time
- One of the Lean Champions for the plant
- Managed and directed 3 direct reports and 75 production employees
- Increased overall productivity by identifying bottlenecks in the production process and proposing effective solutions.
Education
A.A. - Data Analysis
University of Phoenix
B.A. -
California Coast University
10.2024
Skills
- Startup and Co-packer manufacturing experience
- SQF Practitioner
- Preventive Controls for Human Food certified
- Food defense qualified individual
- HACCP Certified
- Lean Certified TMC
- Six Sigma Green Belt Certified
- Strategic Planning
- Autonomous Maintenance Pillar Leadership
- Progressive Maintenance Pillar Leadership
- Health, Safety, Environmental
- Budget Planning and Management
- Capital Planning and Management
- MICROSOFT 365 OFFICE
- EAm
- ERP
- Project Management
- Operations Management
- Production Planning
- Team building and development
- Cost Control
- Regulatory Compliance
- Operational Efficiency
- Workflow Management
- Quality Control Management
Militaryexperience
U.S. Army, E-6, Honorable Discharge
Timeline
Director of Manufacturing
Cascade Coffee
11.2023 - Current
Plant Manager
National Beverage Corp.
07.2019 - 11.2023
Operations Manager
JM Smucker Co. (Formally Sahale Snacks)
11.2017 - 07.2019
Director of Manufacturing
Sahale Snacks
11.2015 - 11.2017
Plant Manager
Sahale Snacks
12.2010 - 11.2015
Plant Manager
Green Garden Foods
09.2008 - 12.2010
Operations Manager
Pathway Medical Technologies
05.2005 - 09.2008
Operations Manager
Campbell Soup Co.
07.1997 - 05.2005
Production Manager
Genie Industries
07.1994 - 07.1997
B.A. -
California Coast University
A.A. - Data Analysis
University of Phoenix
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