Stan Fehr
Director Of Manufacturing
Fort Worth,TX
Summary
General Manager / Managing Director with a demonstrated history of working in the consumer goods industry. Strong operations professional skilled in Lean Manufacturing , Root Cause Analysis, Team Development and Mentoring.
Overview
29
29
years of professional experience
5
5
Certifications
1
1
Language
Work History
Director of Manufacturing and Engineering
DynaEnergetics
12.2022 - Current
- Lead a team of 3 Plant managers and 3 Process Engineers along with 350+ hourly employees across 3 plants producing approximately 1.5 million perforating guns per year
- Championed procurement and implementation of Dozuki training software which enables intuitive SOP development that includes the ability to imbed video
- Increased output from 1.2 in 2022 to 1.5 million finished gun systems in 2023
- Instituted specialized training line to reduce turnover and ensure new employees received standardized experience.
Director of Plant Operations
Russell Stover Chocolates (Lindt)
06.2021 - 06.2022
- Led a team of 14 managers and 20 supervisors along with 1000+ hourly employees producing approximately 24 million lbs
- Of product per year
- Reinvigorated Safety and Quality expectations across the facility
- Restructured very layered org chart to flatter, more focused accountabilities
- Template was utilized across the Russell Stover plant network as a best practice
- Right sized lead positions and saved 2.9MM vs prior years expenses
- Developed Training Manager Role to standardize learning and eliminate reliance on tribal knowledge.
Plant Manager
Treehouse Foods
11.2019 - 06.2021
- Led a team of 5 managers and 10 supervisors along with 250+ hourly employees producing approximately 15 million units of product per year
- Took on the plant manager role at a turnaround plant in 2019
- Plant OEE was improved by 24% from 42% to 52% within the first 6 months of my tenure
- SQF level 2 certification with scores of 96 and 97
- Led team through extremely challenging process changes in FDA thermal process
- Served as content creator for corporate Supervisor Individual Development Planning curriculum
- Navigated COVID 19 successfully at the facility
- The plant never had to shut down despite high infection rates in Bexar County
- No cases of spread within the facility
- Site sponsor for all Lean Process Improvement Teams.
Plant General Manager
Zobele Inc. USA
08.2018 - 09.2019
- Led a team of 5 managers and 6 supervisors along with 100+ hourly employees producing approximately 10 million units of product per year
- Full operational and P&L responsibility
- Successfully led brownfield startup for Zobele Group’s first USA venture
- Delivered Benchmark speed of execution for a new site start-up for our customer Proctor and Gamble (P&G): 10 months from Full Funding to Packing startup and 13 Months to Unstopable Making Startup
- Executed affordability & efficiency, the cost of capacity was 50% lower for Making and 20% lower for Packing than previous P&G startups
- Trained inexperienced staff in Lean Principles, Waste Reduction, 5S, and Trystorming
- Partnered with the P&G team to develop Quality systems and SOPs compliant with their rigorous standards
- Full P&L responsibility including sales volumes and margins.
Plant Manager
Bimbo Bakeries USA
07.2016 - 08.2018
- Led a team of 5 managers and 10 supervisors along with 200+ hourly employees producing approximately 20 million units of product per year
- Improved Material Efficiency from 83.5 to 84.6%
- Added over $200,000 of productivity vs
- AOP
- Increased plant Line Efficiency resulted in additional capacity that enabled the company to add volume to the bakery and away from higher cost per unit plants
- Plant scored 99/100 on 2016 and 2017 SQF certifications
- Implemented vision for Rockwall being an exporter of talent
- Four team members from my organization were promoted to Plant Manager / Production Manger roles
- Led site through Bimbo’s Lean Manufacturing Transformation
- Served on BBU National Safety Observation Team.
Senior Director of Operations
Dr Pepper Snapple Group
01.2014 - 07.2016
- Led all plant operations for Houston and San Antonio Manufacturing plants including a staff of 22 salaried and 500+ hourly associates as well as 7 production/packaging lines producing 30 million cases of finished product annually
- Scope encompasses operations, engineering, maintenance, quality, EHS, and human resources
- Instrumental in leading a cultural and procedural change to achieve best in class results
- Promoted to Sr Director Role in 2014
- Completed DPSG Leadership Program in 2016
- The year-long course is designed to provide training for Director level positions to prepare them for Vice President Roles within the company
- Delivered $914,233 of productivity in Houston and San Antonio in 2015 on a rate per case basis
- Certified Plant under FSSC 22001
- Served as a resource for talent within the organization
- Two members of the Houston team were promoted to Director level positions
- Chosen as a training facility for the DPSG Developing Leader Program
- Mentored incoming leaders throughout a two-year process to prepare them to move to Manager roles at other sites
- Facilitated Site TPM pilot program.
Plant Manager
Dr Pepper Snapple Group
01.2010 - 01.2014
- Led a team of 5 managers and 11 supervisors along with 300+ hourly employees producing approximately 22 million cases of product per year
- Decreased OSHA recordable injuries by promoting a strong safety culture
- Performance improved from a baseline of 12 injuries in 2010 to 2 in 2014
- Increased OEE (Overall Equipment Efficiency) by 11% from 62% to 75%
- Improved Quality scores by 40% from 2.0 to 1.2 CPM
- Progressive improvement of Houston Plant AIB scores from 850 in 2010 to 935 in 2014
- Improved syrup yields by $600,000 vs prior year in 2011
- Implemented water savings projects that have led to over $1,000,000 in cost savings
- Led site Rapid Continuous Improvement/Lean and 5s initiatives
- Selected for DPSG Mentorship Program.
Plant Manager
Coca Cola Enterprises
12.2007 - 01.2010
- Led a team of 11 managers and supervisors plus 100 hourly employees producing approximately 10 million cases of product per year
- Responsible for Operations, Warehousing, Quality and EHS
- Led facility certification in the Coca-Cola Company’s Environmental Management and Safety Management System Audit
- We were the only plant in the entire country to complete the audit with zero non-conformances
- The streamlined compliance manual we developed was identified as a national best practice
- (ISO 9001 and ISO 14001)
- Reduced maintenance downtime by 35% from prior year
- Improved Quality by 29% from 0.7 to 0.5 CPM
- Led 5s initiative that increased storage capacity by over 7 truckloads of finished product
- Increased recycling revenue by 24%
- Reduced warehouse overtime by over 20% to less than 8%
- Order building efficiency increased from 70% to 95%
- Led sites Rapid Changeover / Working capital lean strategy.
Operations Leader
Owens Corning
09.2006 - 11.2007
- Led a team of 4 and supervisors plus 60 hourly employees producing approximately 2.5 million squares of asphalt shingles per year
- Directly responsible for all facets of Roofing Plant including Safety, Throughput, Productivity, Quality, and Operating Efficiency
- Led site Kaizen Events for granule loss and railcar demurrage leading to a combined 350,000 in savings
- Increased engagement scores of direct reports by 12% on Q12 survey
- Reduced downtime due to operator errors by 33%
- Increased pack rates by 18% from 265 squares per hour in 2006 to 315 squares per hour in 2007
- Improved customer complaints from 500 PPM to 299 PPM.
Operations/Technical Resource
Frito Lay
07.2000 - 09.2006
- Led a team of 30 hourly technicians and mechanics in a manufacturing facility producing approximately 70,000,000 cases of product per year
- Created and led implementation of system by which Machine Operators could track packaging labor, material waste and grams giveaway performance on a real time basis
- Recognized by Frito Lay North America as a national best practice
- Site was awarded a $15,000 innovation award for the program
- Saved $70,000 by designing a grams giveaway tracking system that allowed managers to hold their employees accountable for results and reward superior performance
- Implemented a program that empowered frontline technicians by allowing them to calculate the dollar impact of their KPMs and better identify performance gaps
- Resulted in teams developing the capability of performing trade off analysis to improve business results
- Site lead for deployment of new maintenance CMMS
- Developed the first Level 3 team in the San Antonio Plant based off the Frito Lay Continuous Improvement program
- Functioned as new manager mentor in production critical path, policy and procedures and technical skills.
Plant Manager
Griffin and Brand
01.1995 - 07.2000
- Led a team of 20 hourly employees (US) and 100 (Honduras) evaporating, blending and shipping approximately 20,000,000 pound solids of FCOJ
- Directly responsible for all QA, Blend specifications, U.S
- Customs work, Inventory, Logistics, Payroll and Scheduling
- Traveled throughout Mexico and Honduras to facilitate orange juice procurement
- Led greenfield startup of US blending facility
- Developed and implemented inventory program for twelve 70,000-gallon tanks and 15,000 drum frozen storage warehouse
- Served on company’s Board of Directors from 1997-2000.
Education
BA in History with Spanish Minor -
University of Texas Pan American
Skills
Extremely quick learner
Engineering/project management experience
Cross-Functional Collaboration
Operational Efficiency
Customer Satisfaction
Equipment Troubleshooting
Cost Reduction
Problem-Solving
Workforce Development
Preventive Maintenance Programs
Analytical Thinking
Continuous Improvement
Certification
Six Sigma Green Belt Trained
Timeline
Director of Manufacturing and Engineering
DynaEnergetics
12.2022 - Current
Director of Plant Operations
Russell Stover Chocolates (Lindt)
06.2021 - 06.2022
Plant Manager
Treehouse Foods
11.2019 - 06.2021
Plant General Manager
Zobele Inc. USA
08.2018 - 09.2019
Plant Manager
Bimbo Bakeries USA
07.2016 - 08.2018
Senior Director of Operations
Dr Pepper Snapple Group
01.2014 - 07.2016
Plant Manager
Dr Pepper Snapple Group
01.2010 - 01.2014
Plant Manager
Coca Cola Enterprises
12.2007 - 01.2010
Operations Leader
Owens Corning
09.2006 - 11.2007
Operations/Technical Resource
Frito Lay
07.2000 - 09.2006
Plant Manager
Griffin and Brand
01.1995 - 07.2000
BA in History with Spanish Minor -
University of Texas Pan American