VirtualResume / Plasitics processing lean manufacturing manager with 29 years experience in problem solving, cost reduction, customer service with strong interpersonal and team skills. (3537385)
Kenneth Klatt
Name: Kenneth Klatt
Phone: 973-729-4083
E-Mail: kgk...@yahoo.com
Location: Sparta, NJ US
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KENNETH G. KLATT
6 Crystal Rock Road Phone:(973)729-4083
Sparta, NJ 07871 Cell:(973)903-5574
Email: kgk...@yahoo.com
OPERATIONS EXECUTIVE
Automotive and Building Products Industries
Manufacturing executive with a record of accomplishments including
turnaround, start-up and ongoing operations management. Expert at
resolving problems, implementing cost reduction and improving customer
service levels to achieve improved profitability and revenue growth.
Equally effective at new product introduction from product/process design
through manufacturing standardization. Specific expertise in World Class
Manufacturing principles and streamlining operations. Participative team
player and communicator to focus resources on a shared commitment to
business objectives.
PROFESSIONAL EXPERIENCE
Vinyl Building Products Inc., Oakland, NJ 2/94 to 12/00
A $61MM PVC profile extrusion manufacturing division of ThyssenKruppAG, a
$40B multinational manufacturing conglomerate. Full acquisition in 1999.
VICE PRESIDENT MANUFACTURING/DIRECTOR CONTINOUS IMPROVEMENT:
Responsible for manufacturing, logistics, quality, tooling, engineering,
product development, environmental impact and capital budgets.
210 employees, 3 facilities, 30 product lines, 3000+ SKU's
- Supported sales gain of 225% in 4 years; new customer growth from 42 to 77.
- Increased labor productivity 236% through lean manufacturing technologies,
targeted investments, Total Productive Maintenance and 5S
housekeeping.
- Engineered design, and equipment and tooling selection of focused
operation in Little Rock, AR; production 5 months after groundbreaking;
promoted the Plant Manager and hired staff.
- Reduced customer complaints 20 fold and in house rejections through quality
systems development and reinforcement.
- Implemented internal recycling and reused 75% of waste.
- Improved production and inventory management systems; line fill rate
increased to 96.7%, customer backorders reduced, lead-time cut 8 days to 3
days using work center balancing, capacity analysis, inventory
turnover and bar coding system.
- Directed the development of the companies first internally manufactured
PVC compound; follow-up optimizations for lower cost and higher
throughput capability; 20% material savings.
- Organized and participated in the development of a PVC foam composite
for use in an industry first thin wall Celuca window (patent application).
- Led the continuous improvement and re-engineering program: employed cross
functional teams working intensely for 90 days targeting breakthrough
results; (2) projects generated savings of $1.6MM and a 57% cycle reduction
time; Overall cost of goods sold reduced 15%.
- Reviewed Market requirements and developed and updated the 5-Year
Operations Strategic Plan; capital investment planning and control;
annual investments of $5MM to $6MM.
- Outsourced low volume, high cost parts and freight services to focus
resources, reduce cost and provide capacity; shared technologies
to improve quality and lower costs.
Standard Products Company, Inc., Cleveland, OH 10/89 - 2/94
Manufacturer of plastic and rubber components serving the OEM
Automotive Industry; Sales $800MM.
DIVISION MANAGER: Canadian Plastic Division, Mississauga, Ontario, Canada
Produce profile extrusions, metal-plastic co extrusions and
injection molded components serving GM, Chrysler and Tier 1 companies:
Sales $60MM, 2 plants (union), P&L responsibility.
- Reorganized operations for improved responsiveness and teamwork;
3 plants consolidated to 2.
- Implemented Total Quality Management philosophy for focus on customer
satisfaction and financial performance; key metrics on labor, cost of
quality, line fill, inventory and capacity utilization.
- Reduced costs $4MM to $5MM offsetting price concessions, and improved
profit margins; employed Kaizen to generate higher quality, reduced
reduced lead-time and greater throughput; floor space, inventory and
labor savings of 30% to 50%
- Commercialized 20 new products requiring new technologies, materials and
processes; used Advanced Quality Planning, empowered employees, Program
Management and targeted investments.
- Expanded manufacturing controls to improve performance, lower scrap and
achieve higher production schedule performance.
DIVISION MANAGER: Campbell Plastic Division, Schenectady, NY.
Profile extrusions and injection molded components serving FORD.
Sales $45MM, Q1 rated, union plant, P&L responsibility.
- Directed the installation of $5MM processing equipment and tooling for new
inventory reduction of $4.5MM in 9 months; process scrap reduced 40%.
product combining extrusion and injection molding technologies; used
Value Analysis/Value Engineering to reduce non-value added operations.
- Launched five new multicolored products for 1992 Model Year affecting
90% of the Division Sales base.
- Implemented cost reductions of $2.8MM through material development and
reuse, process optimization and elimination of non-value added
costs;
Echlin Inc., Branford, CT 8/78 - 10/89
Produce automotive parts for Replacement and OEM; Sales $1.4B
DIVISION MANAGER: Prattville Manufacturing Inc., Prattville, AL
Sales $42MM achieved in 2 years, P&L responsibility, 2 plants, non-union,
Greenfield project: manufacture non-asbestos heavy duty brake products for OEM
and Replacement; profitable within 13 months of groundbreaking.
PLANT MANAGER: Heavy Duty Products; Peterborough, Ontario
Sales $15MM, P&L responsibility, union plant; converted $800K loss to
$1.0MM profit by increasing throughput and customer service, and cost
reduction. Business relocated to Alabama when technology converted to
non-asbestos.
MANAGER of ENGINEERING: Brake Systems Division, Stratford, CT
Responsible for Process, Manufacturing, Industrial and Maintenance Engineering.
Achieved cost reduction of $1.5MM through focus on project planning and control.
CHIEF ENGINEER, SENIOR PROJECT ENGINEER: Brake Systems Division
Responsible for development and startup of non-asbestos products; awarded
first OEM contract (Ford F250).
PATENTS: U.S. Patent 3.966,657 epoxy resin catalyzation
PROFESSIONAL DEVELOPMENT:
MBA Program at Troy State University, Montgomery, AL.
Completed financial, marketing and organizational development
courses prior to relocation to New York.
B.A. Chemistry UNIVERSITY of WISCONSIN
Juran on Quality Improvement KAIZEN Continuous Improvement
KepnorTregoe Problem Solving Advanced Project Management
Statistical Process Control Excel---Word---Lotus 123
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