Shaun N Laface
Somerset,PA
Summary
Operations Manager with extensive experience in manufacturing and a proven track record in driving efficiency and performance improvements. Successfully led initiatives that reduced operational costs, enhanced throughput, and implemented safety programs resulting in significant incident reductions. Seeking a Plant Manager or Director of Operations role to leverage expertise in operational excellence.
Overview
26
26
years of professional experience
Work History
Director of Operations
American Beverage Corp
Verona, PA
07.2023 - Current
- Oversees business operations of a 250-million-dollar manufacturing plant.
- Oversaw business operations for 320,000 square foot distribution center, ensuring efficient processes and effective resource allocation.
- Led cross-functional project team of ten employees to improve machine reliability, reducing operational costs and increasing throughput.
- Leading effort to redesign distribution center, reducing footprint by 10%.
- Developed internal Key Performance Indicators and implemented Safety, Quality, Delivery, Cost methodology at both locations to enhance operational performance.
- Manages operations budget for two facilities.
- Launched Plant Safety Committee, reducing recordable incidents by 50% YTD
Plant Manager
Weston Foods
Somerset, PA
04.2021 - 07.2023
- Exceeded all organizational KPIs during tenure as plant manager.
- Managed daily operations of manufacturing plant, ensuring alignment with organizational goals.
- Navigated successful FDA and BRC audits, achieving AA BRC status.
- Supervised sixty salaried, production, warehouse, and human resources personnel, fostering a cohesive team environment.
- Facilitated two SAP software launches at the manufacturing plant, coordinating team efforts and timelines.
- Developed and implemented training and performance plans for all personnel, enhancing team skills and accountability.
- Conducted needs assessment and closed human resource gaps in all critical positions.
Industrial Engineer
Spherion (Lockheed Martin)
Johnstown, PA
09.2020 - 04.2021
- Implemented Total Quality Check methodology across processes and documents to ensure consistent quality standards.
- Rewrote work instructions to enhance process flow and operator understanding, contributing to improved throughput.
- Collaborated with production leads to identify and document specific process improvements.
Plant/Production Manager
Bacharach
New Kensington, PA
01.2020 - 07.2020
- Managed 2 Supervisors and a workforce of sixty production, warehouse, and shipping personnel.
- Directed morning stand-up meetings, aligning production and purchasing activities with operational goals.
- Redesigned morning meeting and Gemba walk format to enhance team engagement and focus on key performance metrics. focusing on customer facing measurables & addressing material issues.
- Collaborated with manufacturing engineers to enhance training on critical lines, fostering a skilled workforce and elevating product quality.
- Implemented total quality check methodology in all processes, ensuring improved quality, and a reduction in assembly errors.
- Reconciled RMA process, improving process flow and reducing turnaround by 25%.
- Conducted plant-wide inventory assessment, increasing inventory accuracy and improving job completion rates while minimizing stock out occurrences.
Operations Manager/World Class Manufacturing Project Manager
Saint-Gobain Ceramics
Latrobe, PA
06.2015 - 11.2019
- Directed continuous improvement program, achieving significant process improvements and cost savings across the plant.
- Led organizations cross functional steering committee focusing on Key Performance Indicators and cost saving initiatives.
- Launched press throughput initiative, resulting in 10% increase in Overall Equipment Effectiveness across the board.
- As WCM Manager, trained plant personnel in various facets of WCM methodology.
- Successfully navigated the plant through its first World Class Manufacturing audit, achieving an absolute score of 11, and a contribution score of 18.5.
- Developed quality program, including total quality check which was instrumental in organization receiving autonomous vehicle contract.
- Launched ISO Press 6S initiative, reducing setup time by 50% to improve operational efficiency.
- Supervised 3 pre-engineered functions, managing seven associates to enhance production effectiveness.
- Realized sustained improvement of 20% in productivity since assuming responsibility for Pre-engineered department.
- Performed production planning and scheduling function for pre-engineered group, approving organizations weekly workflow, approving delivery dates, all the while achieving a throughput rate of 1.5 (plan vs actual at Water Jet).
- Redefined new business review process resulting in improved production planning and eliminating overscheduling.
- Successfully closed two capital expenditure projects ensuring business continuity and annual labor cost avoidance of $15,000 associated with non-value-added activity.
- Applied lean concepts to water jet operation, reducing labor cost by 20% from 2017 to 2018.
- Led plant-wide value stream map exercise, identifying twenty-six kaizen (Quick & other) possibilities.
Manufacturing Engineering Technician (Industrial Engineer)
Philips / Respironics
Murrysville, PA
01.2001 - 01.2015
- Co-led initiative to redesign primary product line, increasing throughput on first shift, and eliminating the need to launch second shift, resulting in cost avoidance of approximately $1,800,000.
- Increased manufacturing plants throughput capacity by 75%.
- Primary product increase in units per labor hour, from .86 to 1.98.
- Product line raw material inventory reduction of $95,128 (Chicago line).
- Determined root cause of internal part shortages, and implemented solution, resulting in decreased down time, increased throughput, and reduced online raw material inventory.
- Applied DFT methodology to production lines, ensuring adequate material flow without housing excess inventory on said lines.
- Applied DFT methodology, reducing operational cycle time for all product lines.
- Deployed DFT tactics to organizational internal supply chain, increasing supply chain throughput, reducing online inventory, and reducing line footprint.
- Mentored manufacturing technicians on demand flow technology methodology, assisting them in setting up product lines, reducing online raw inventory and improving throughput.
- Developed DFT Training Module and all templates which are still in use by Murrysville facility, resulting in: Process standardization (Standard work), which, in turn, led to a 25% reduction in assembly errors.
- Collaborated with team to implement total quality checks across all lines, ensuring consistent product quality.
- Conducted pilot runs, inspection qualifications and process validations.
- Managed capital asset purchasing, including annual capital needs assessments, budget planning, acquisition planning, and execution.
- Managed supplier relations, negotiating prices and assessing supplier capabilities to align with business objectives.
- Updated Kanban replenishment model, resulting in on time delivery of materials, while keeping raw material WIP at a minimum.
- Co-led team responsible for redesigning manufacturing floor layout, resulting in: Overall floor space reduction of 2000 square feet, resulting in monthly overhead cost avoidance of $8240 (2000 X $4.12).
- Negotiated the purchase of high-volume duplicator, saving the organization $47,000.
- Co-led team responsible for traveling to Framingham Massachusetts, integrating five new products/processes into Murrysville plant.
- Trained new assemblers during new product integration.
- Generated monthly Trilogy line yield report detailing failure modes, exceptions, defect rates, and planned corrective actions to enhance quality monitoring.
Education
MBA - Strategic Planning
University of Phoenix
Bachelor’s degree - business/accounting
University of Phoenix
Comprehensive Six-Sigma Black Belt Certified -
University of Villanova
Comprehensive Lean Manufacturing Certified -
University of Villanova
Demand Flow Technology (DFT) Certified -
Demand Point
Academic Achievement Award -
United States Air Force Non-Commissioned Officer Leadership School
Skills
- Project management
- Budget management
- Process optimization
- Performance metrics
- Quality assurance
- Change management
- Operational safety
Education Certifications
- MBA, Strategic Planning, University of Phoenix
- Bachelor’s degree, business/accounting, University of Phoenix
- Comprehensive Six-Sigma Black Belt Certified, University of Villanova
- Comprehensive Lean Manufacturing Certified, University of Villanova
- Demand Flow Technology (DFT) Certified, Demand Point
- World Class Manufacturing (WCM) methodology
- Academic Achievement Award, United States Air Force Non-Commissioned Officer Leadership School
Summary Objective
Results-driven Operations Manager with 20 years of experience in manufacturing operations, leadership, and continuous improvement. Seeking a Plant Manager or Director of Operations position where I can leverage my expertise in operational excellence, process optimization, team development, and strategic leadership to drive performance, improve efficiency, and support organizational growth.
Timeline
Director of Operations
American Beverage Corp
07.2023 - Current
Plant Manager
Weston Foods
04.2021 - 07.2023
Industrial Engineer
Spherion (Lockheed Martin)
09.2020 - 04.2021
Plant/Production Manager
Bacharach
01.2020 - 07.2020
Operations Manager/World Class Manufacturing Project Manager
Saint-Gobain Ceramics
06.2015 - 11.2019
Manufacturing Engineering Technician (Industrial Engineer)
Philips / Respironics
01.2001 - 01.2015
MBA - Strategic Planning
University of Phoenix
Bachelor’s degree - business/accounting
University of Phoenix
Comprehensive Six-Sigma Black Belt Certified -
University of Villanova
Comprehensive Lean Manufacturing Certified -
University of Villanova
Demand Flow Technology (DFT) Certified -
Demand Point
Academic Achievement Award -
United States Air Force Non-Commissioned Officer Leadership School