Thomas M. Zapfe II
Owosso
Summary
Motivated and goal-oriented manufacturing maintenance and operations management professional with 13 years of experience. Seeking a high-impact role within a rapidly advancing company to further contribute to its success. Demonstrated ability in optimizing production efficiency, reducing downtime, and implementing cost-effective strategies. Skilled in leading cross-functional teams, fostering collaboration, and driving continuous improvement initiatives. Looking for an opportunity to leverage expertise in driving operational excellence and delivering measurable results in a dynamic and challenging environment.
Overview
15
15
years of professional experience
Work History
Maintenance Supervisor
Michigan Sugar Company
12.2024 - 03.2025
- Ensured employee adherence to regulatory and company safety requirements.
- Ensured equipment adhered to environmental regulations.
- Contributed to managing the maintenance department for business goal attainment.
- Ensure compliance with Feed & Food safety program standards in relation to USDA & SQF requirements.
- Managed and adhered to R&M budget through capital planning, improving controllable margin, and controlling losses.
- Assessed reliability by analyzing Mean Time to Repair and Mean Time to Failure.
- Played a key role in deploying KPI utilization for assessing equipment efficiency and comprehensive maintenance expenses.
- Directed all aspects of preventative, predictive, and reactive maintenance.
- Optimized maintenance by managing costs and tracking performance through AMMS.
- Facilitated creation of maintenance goals and timelines.
- Track results and take corrective actions as appropriate to achieve goals
- Oversaw Parts Warehouse operations, focusing on asset control and usage tracking.
- Adhered to established policies and procedures in purchasing activities.
- Implemented development initiatives ensuring the appropriate application of resources for current and future needs.
- Identified and submitted capital projects enhancing operational efficiency.
- Collaborated across departments on internal quality and compliance audits.
- Oversaw updates and additions to facilities, working closely with service providers.
Plant Engineering Manager
Dart Container
08.2024 - 12.2024
- Directed oversight of two supervisors indirectly responsible for 22 maintenance staff.
- Directed maintenance planning and oversight for 122 injection molding machines.
- Directed efforts for significant project completions, including high-pressure boiler commissioning and facilities upgrades.
- Updated budget status and maintenance reports in daily meetings with upper management.
- Conducted onsite projects during Darts Operational Excellence University, enhancing product throughput.
Maintenance Manager
ACI Plastics
01.2024 - 08.2024
- Directed maintenance operations across various facilities.
- Completed integration of new software into company processes to streamline performance monitoring.
- Identified vendors that contributed to significant cost savings and reduced equipment downtime.
- Mentored and developed skills of two new machine repair technicians.
- Created and led the company's Continuous Improvement Teams.
- Managed salaried supervisors and hourly techs.
- Led two projects valued at 25K and 100K, achieving completion weeks ahead of schedule while saving costs.
- Generated favorable results through completion of 100K project.
Maintenance and Operations Director
Corunna Public Schools
04.2023 - 02.2024
- Saved over $100K for the school district by optimizing utilities expense.
- Developed comprehensive maintenance schedule for all district buildings and equipment.
- Managed comprehensive summer district shutdown, yielding significant completion of long-neglected projects.
- Performed full-scale thermal imaging of district-wide electrical switchgear.
- Educated personnel on predictive maintenance best practices.
Maintenance Manager
Michigan Sugar Company
09.2020 - 04.2023
- Reduced mechanical downtime leading to 36% decrease in lost revenue over tenure period.
- Boosted work order efficiency to 75% from under 5%.
- Oversaw operations involving millwright, welding, pipe fitting, machining, and fabrication with a team of 4 supervisors and 40 technicians.
- Directed comprehensive shut down operations during a 4-month timeframe.
- Designed predictive maintenance program utilizing thermal scans, vibration analysis oil filtering and analysis.
- Oversaw implementation and final delivery of various capital initiatives within project timelines.
- Oversaw a digital maintenance system, ensuring accurate cost documentation.
- Revamped the facility's safety program, encompassing areas such as walking working surfaces, lockout/tagout procedures, and permit-required confined spaces management.
- Served on corporate team driving continuous improvement initiatives.
- Contributed to decisions and initiatives of the facility apprenticeship board.
- Direct end-to-end upkeep operations across a 220-acre site.
Maintenance/ Engineer Associate Supervisor
PepsiCo
08.2015 - 09.2020
- Directed a team of 17 Maintenance Technicians in preventive and corrective maintenance across five beverage processing lines.
- Enhanced skills and knowledge base of Maintenance Technicians through continuous development.
- Maintained high levels of equipment reliability, resulting in increased productivity.
- Analyzed conservation efforts during audits for both locations.
- Identified over 40 utility-saving opportunities for the plant in recent audits.
- Directed Total Productive Maintenance Preventive Maintenance team.
- Enhanced workplace safety standards resulting in top audit marks for Global Health Environmental Safety Management.
- Evaluated and managed vendor proposals for diverse equipment upgrades.
Communications Electronics Maintenance Supervisor
US Marine Corps
06.2010 - 05.2015
- Supervised corrective maintenance operations across 500 communications, intelligence, and topographic units.
- Sustained mission readiness above 90% for equipment inventory exceeding two and a half years.
- Conducted training for 60 communications and intelligence personnel on maintenance procedures.
- Awarded a commendation for implementing and managing a new technical publication management system.
- Led biannual preventive and corrective maintenance on 46 intelligence and topographic analysis systems valued at $4.5M.
- Executed advanced troubleshooting on TROJAN SPIRIT LITE satellite system to identify issues.
- Conducted advanced maintenance tasks for specialized military surveillance equipment.
- Expertly handled tasks within the CMMS platform.
- Conducted preventive and corrective maintenance on Harris Multiband Radio Suites.
- Established new protocols to address gaps in shipping and receiving operations.
- Developed comprehensive yearly training plans for 25 staff members.
- Developed an Operational Risk Management (ORM) training program to ensure adherence to safety guidelines.
Education
Bachelors of Science - Project Management
Colorado Tech University
Skills
- Communication
- Problem Solving
- Maintenance Troubleshooting
- Preventative and Predictive Maintenance
- Leadership
- Detail Oriented
- Order Management
- Project Management
- Technical Writer
- Sound Decision Making
- Continuous improvement
- Lean manufacturing
- Operations management
- Asset management
- Asset health
- Reliability
Training And Certificates
- Advanced Maintenance Leadership Program, PepsiCo University
- Dale Carnegie Develop Your Leadership Potential, Dale Carnegie
- Infor CMMS Training Course, Advoco INC.
- Pump 101 engineering course, Proflow Pumping Solutions
- Lean Six Sigma Yellow Belt, PepsiCo University
- Maintenance Planning/ Scheduling
Attributes
- Communication
- Problem Solving
- Maintenance Troubleshooting
- Preventative and Predictive Maintenance
- Leadership
- Detail Oriented
- Order Management
- Project Management
- Technical Writer
- Sound Decision Making
- Continuous improvement
- Lean manufacturing
- Operations management
Timeline
Maintenance Supervisor
Michigan Sugar Company
12.2024 - 03.2025
Plant Engineering Manager
Dart Container
08.2024 - 12.2024
Maintenance Manager
ACI Plastics
01.2024 - 08.2024
Maintenance and Operations Director
Corunna Public Schools
04.2023 - 02.2024
Maintenance Manager
Michigan Sugar Company
09.2020 - 04.2023
Maintenance/ Engineer Associate Supervisor
PepsiCo
08.2015 - 09.2020
Communications Electronics Maintenance Supervisor
US Marine Corps
06.2010 - 05.2015
Bachelors of Science - Project Management
Colorado Tech University
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