Shane Ford
Le Mars,Iowa
Summary
Decisive Production Supervisor exceptionally skilled at identifying measures to improve production methods and equipment performance. Consistently achieved inventory goals and maintained minimal downtime for production lines.
16 years experience in manufacturing as a general practitioner of Lean and Six Sigma. In my most recent assignment, I led my team with 0 recordable injuries in 120 work days. In that same time period, I taught my team to decrease cycle time by 17%, increase average total output by 11 %, reduce downtime by 7%, and reduce scrap rate by 13%. Besides these notable metrics, my most satisfying accomplishment was getting 33 direct reports cross-trained in three functional operator roles, developing, and implementing a weekly job rotation schedule to assure job proficiency.
Overview
14
14
years of professional experience
1
1
Certification
Work History
Production Supervisor
Dairy Farmers Of America
10.2023 - Current
- Lead pre Shift huddle and communicated crewing assignments
- Identified plant equipment that needed maintenance attention and created notifications through SAP
- Identified suspect or non-conforming materials and finished goods
- Made notifications for immediate quarantine and FSQA disposition
- Lead RCA meetings and continuously improved operations by using Lean and Six Sigma tools and methodology, using D.M.A.I.C and SPC
- Managed to improve labor rates and total production
- Assisted HR with new hire onboarding, orientation and training
- Conducted area safety audits and constantly looked for safety, PPE and GMP deficiencies
- Performed end of shift passdown
Production Supervisor
Cargill
01.2023 - 05.2023
- Lead pre Shift startup stretching warmups and crewing assignments
- Collaborated with the plant scheduler to set work schedules
- Prepared in advance for and addressed production problems, material deficits, equipment failures, and unavoidable delays.
- Managed SAP and plant schedule to ensure takt times for work cells and production lines meet or exceed work standard for output
- Identified plant equipment that needed maintenance attention and created notifications through SAP
- Identified suspect or non-conforming materials and finished goods
- Made notifications for immediate quarantine and FSQA disposition
- Lead RCA meetings and continuously improved operations by using Lean and Six Sigma tools and methodology, using D.M.A.I.C and SPC
- Implemented policies and standard operating procedures for continuous improvement.
- Spearheaded Continuous Improvement projects to eliminate inefficiencies with energy
- Managed to improve labor rates and total production
- Assisted HR with new hire onboarding, orientation and training
- Conducted area safety audits and constantly looked for safety, PPE and GMP deficiencies
- Performed end of shift passdown, and inventory reconciliation reports.
Production Supervisor
Smithfield
08.2021 - 02.2022
- Supervised Shipping and Receiving Departments for incoming fresh meat and outgoing finished goods
- Lead pre Shift startup stretching warmups and crewing assignments
- Collaborated with the plant scheduler to set work schedules
- Managed SAP and ADC schedule to ensure takt times for work cells and production lines meet or exceed work standard for output
- Identified plant equipment that needed maintenance attention and created notifications through SAP
- Identified suspect or non-conforming materials and finished goods
- Made notifications for immediate quarantine and FSQA disposition
- Lead RCA meetings and continuously improved operations by using Lean and Six Sigma tools and methodology, using D.M.A.I.C. and SPC
- Spearheaded Continuous Improvement projects to eliminate inefficiencies with energy
- Managed to improve labor rates and total production
- Assisted HR with new hire onboarding, orientation and training
- Conducted area safety audits and constantly looked for safety, PPE and GMP deficiencies
- Continuously monitored HACCP conditions and USDA paperwork, as well as adherence to SSOP requirements
- Performed end of shift passdown, RPM reporting, and inventory reconciliation reports
Technician Pre-Finish Department
Pella Corporation
07.2018 - 06.2021
- Conducted informal line performance review with first shift personnel to assure smooth transition for shift handoff
- Verified on time Quality Checks for shift startup
- Communicated team resource needs with regard to Safety, Quality, Productivity, and Maintenance
- Continuously monitored quality levels and productivity performance relative to company goals, providing downtime diagnostic and immediate remediation.
Quality Assurance Supervisor
Liguria
10.2015 - 06.2018
- Lead a staff of food quality technicians with regard to SQF standards for food safety
- Served as primary contact for USDA officers and inspection
- Authorized release of production areas to Plant Manager upon completion of rigorous preoperative inspection findings by assigned QA staff
- Performed company audits for continuous SQF compliance and Re-Certification
- Managed Preventative and Corrective Action records for plant operations
- Managed food safety laboratory (on site) location
- Acted in the capacity of Quality Manager during times of role vacancy, reporting directly to the Director of Food Safety and Quality.
Production Team Manager
Van Diest Supply Company
12.2009 - 10.2015
- Performed preoperative inspection and TPM on equipment, as required for plant needs
- Improved production efficiency by implementing lean manufacturing techniques and optimizing team workflows
- Reviewed and evaluated batch records for accuracy in the formulation of plant herbicides for such customers as: DuPont, Dow, Syngenta, Monsanto, BASF, and others
- Approved hot work permits
- Analyzed production data and prepared reports for senior management
- Lead small teams to assure equipment readiness for R/D trials and first run approval
- Supervisor for confined space entry.
Education
Bachelors of Arts -
Simpson College
Indianola, Iowa12.1993
Skills
- Quality Engineering - Certified 2008-2010
- Continuous Improvement
- Lean Manufacturing
- Six Sigma (Green Belt) through ASQ
- HACCP Certification in 2017
- LOTO experience
- Confined Space experience
- Hot Work Permit experience
- Proficient in Microsoft Suite
Certification
- 2008, Certified Quality Engineer (CQE)
- 2009, Certified Quality Manager of Organizational Excellence (CQM/OE)
- 2009, Certified Six Sigma Green Belt (CSSGB)
Timeline
Production Supervisor
Dairy Farmers Of America
10.2023 - Current
Production Supervisor
Cargill
01.2023 - 05.2023
Production Supervisor
Smithfield
08.2021 - 02.2022
Technician Pre-Finish Department
Pella Corporation
07.2018 - 06.2021
Quality Assurance Supervisor
Liguria
10.2015 - 06.2018
Production Team Manager
Van Diest Supply Company
12.2009 - 10.2015
Bachelors of Arts -
Simpson College
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