TONY CALK
Temple
Summary
Dynamic manufacturing manager with a proven track record of cultivating high-performing teams that drive operational excellence. Expertise in developing strategic action plans to enhance safety, quality, performance, and productivity across diverse manufacturing processes. Strong proficiency in operations management, including budgeting, cost controls, and lean methodologies, ensures continuous improvement and effective resource utilization. Committed to fostering a culture of innovation and efficiency through robust team development and meticulous process optimization.
Overview
25
25
years of professional experience
Work History
Plant Superintendent
Lane Enterprises
07.2025 - Current
- Supervised daily operations to ensure production targets and quality standards were consistently met.
- Implemented process improvements that enhanced operational efficiency and reduced waste across production lines.
- Trained and mentored staff in safety protocols, machinery operation, and best practices for optimized workflow.
- Collaborated with maintenance teams to schedule preventative maintenance, minimizing downtime and improving productivity.
Continuous Improvement Manager
Mooreco
12.2024 - 05.2025
- Led operational improvement efforts across production cells, emphasizing lean manufacturing and cell balancing.
- Facilitated daily Gemba walks and problem solving sessions to support shop floor engagement and ownership.
- Standardized operational processes through visual controls and documentation, reinforcing operational basics and accountability.
Plant Manager
Pactiv-Evergreen Corporation
11.2023 - 12.2024
- Responsible for overall plant operations and financial oversite.
- This site produces rigid display plastic containers. 18 formers, 1 inline and 7 extruders. 235 employees.
- Performed 360 hand Gembas to reduce these types of injuries from prior year (4)-zero YTD.
- CI activities totaling 2.5MM-material usage variance, centralized delivery system, gauge reduction programs.
- AA+ unannounced BRC audit.
- Initiated time studies SKU to find opportunities for labor optimization.
- Utilized the RTC process to refurbish/repair tooling-raising OTIF from 72.90 PY to 87.23 YTD.
- Company Overview: Pactiv Evergreen is one of the largest manufacturers of fresh food & beverage packaging in North America.
Plant Manager
Pactiv-Evergreen Corporation
04.2020 - 10.2023
- Responsible for overall plant operations and financial oversite.
- This site produces rigid display plastic containers. 160 employees.
- Consistent OEE 83-85%.
- 823 days without a safety incident.
- 2 years without a quality incident.
- BRC AA certified 5 years in a row.
- CI activities resulting in 500K savings in 2022.
- Company Overview: Pactiv Evergreen is one of the largest manufacturers of fresh food & beverage packaging in North America.
Production Manager
Pactiv-Evergreen Corporation
02.2019 - 04.2020
- Responsible for the forming and extrusion departments for Foam.
- Involved in all aspects of the business unit including productivity, corrective action, quality audits, safety Gemba walks, and coaching katas.
- Responsible for tracking direct labor cost, production, and overtime for the entire Temple facility.
- Involved in Level 4 savings programs, yearly and monthly business forecasts, material usage variance, job postings and interviews, and capital requisition requests.
- Company Overview: Pactiv Evergreen is one of the largest manufacturers of fresh food & beverage packaging in North America.
Production Supervisor
Pactiv-Evergreen Corporation
12.2017 - 02.2019
- Supervisor for the entire Foam forming unit consisting of 300 employees.
- Responsible for the training, corrective action, productivity, and counter measures across the production unit.
- Involved in all aspects of production, safety, and quality in the Foam unit including Tier 1 and 2 meetings, A3, kaizen, safety Gemba's, production charts, time/attendance, weekly KPIs, quality and safety audits both daily and weekly.
- Improved OEE over the course of the year from 63% to 70%.
- Increased productivity by 5 million pounds to date in the department.
- Installed a startup plan during plant shutdowns which reduced initial downtime by 25%.
- Company Overview: Pactiv Evergreen is one of the largest manufacturers of fresh food & beverage packaging in North America.
Production Supervisor
Pactiv-Evergreen Corporation
06.2013 - 12.2017
- Supervisor: manage 60-85 employees.
- Approved cost centers, manage staffing and materials, submit reports daily concerning productivity, quality, safety, and staffing.
- Responsible for conducting Tier 1 meetings and monthly shift safety training.
- Conducting disciplinary actions/procedures, visualization and implementation of various process/procedure adjustments to directly impact production growth.
- Address quality complaints and appraising performance.
- Team Leader: managed 27-35 employees.
- Direct reports to the supervisor including state of machinery, daily production status, daily staffing, completing time/attendance, closing production orders, and entering production data.
- Machine operator: Responsible for the installation and startup of Saliba machines in the new EPS Corsicana facility.
- Saliba machine trouble shooting, size changeovers, replacing broken parts, and ensuring quality product.
- Consistently averaged 72% uptime over the course of 5 years.
- Carried a CQC of 1.26 for the shift vs a 6.85 for the entire EPS unit.
- Developed training programs for C operators which increased productivity and decreased operator turnover.
- Company Overview: Pactiv Evergreen is one of the largest manufacturers of fresh food & beverage packaging in North America.
Machinist
3TR Group
10.2010 - 11.2012
- Basic offsets and setup for various 5 tool CNC machines.
- Responsible for individual machined parts production.
- Basic G code machine programming.
- Privately Held CNC machining
- Company Overview: Privately Held CNC machining
Supervisor
R&S Commercial Painting
04.2001 - 09.2010
- Supervised 10-15 personnel for commercial projects.
- Responsible for expenses, labor, and project deadlines.
- Private commercial painting
- Company Overview: Private commercial painting
Education
B.A. - English Literature
University of Texas At Arlington
Arlington, TX05-2004
Skills
- Manufacturing Excellence
- Action Plans
- Safety
- Quality
- Performance
- Productivity
- Team Building
- People Development
- Financial Acumen
- Continuous Improvement
- Plant Management
- Lean Plant Management
- Inventory Control
- Scheduling
- Purchasing
- Quality Control (QC)
- Statistical Process Control (SPC)
- Material Requirements Planning (MRP)
- Production Planning
- Reporting
- Engineering
- Maintenance
- Capital Equipment Purchase
- Installation
- Troubleshooting
- Productivity Improvement
- Distribution
- Regulatory Compliance
- Process Improvement
- Root Cause Analysis
- Lean Six Sigma
- Budgeting
- Cost Controls
- Utility Management
- Sourcing Raw Materials
- Capacity Planning
- New Product Development
- Cost Reduction Initiatives
- Plant Expansions
- Start-up Operations
- Equipment Upgrades
- Daily Operations
- Plant and warehouse operations
- Administering budgets
- Safety practices
- Controlling costs
Timeline
Plant Superintendent
Lane Enterprises
07.2025 - Current
Continuous Improvement Manager
Mooreco
12.2024 - 05.2025
Plant Manager
Pactiv-Evergreen Corporation
11.2023 - 12.2024
Plant Manager
Pactiv-Evergreen Corporation
04.2020 - 10.2023
Production Manager
Pactiv-Evergreen Corporation
02.2019 - 04.2020
Production Supervisor
Pactiv-Evergreen Corporation
12.2017 - 02.2019
Production Supervisor
Pactiv-Evergreen Corporation
06.2013 - 12.2017
Machinist
3TR Group
10.2010 - 11.2012
Supervisor
R&S Commercial Painting
04.2001 - 09.2010
B.A. - English Literature
University of Texas At Arlington