1john A. Zacharias 313 West 7th Street Marysville, Ohio 43040

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1John A. Zacharias 313 West 7th Street Marysville, Ohio 43040 Cell: 937-243-8469 Home: 937-642-5588 Email: [email protected] PROJECT MANAGER PROCESS IMPROVEMENT/INDUSTRIAL ENGINEERING/DISTRIBUTION ENGINEERING Results-driven, improvement and quality-focused engineering professional with broad experience managing manufacturing, distribution, and supply chain projects and leading teams to LEAN concept deliverables. Solid manufacturing and distribution background with proven success in re-engineering processes, achieving cost-saving initiatives, and working with management, labor, and vendors to meet or exceed project goals. Consistently meets aggressive deadlines with project success while performing “hands-on” in fast-paced, time-sensitive environments. Strong communicator and team leader able to motivate for successful project results. Strengths include:

□ Project Management Handling □ LEAN Manufacturing Design □ SIX Sigma/ISO-9000 Layout Design □ Kaizen/Continuous Improvement Installations/Start-ups □ EPA/OSHA Compliance

□ Strategic Planning

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□ Budgeting/Forecasting

□ Warehouse System

□ Cost Analysis – labor, supply chain

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□ Vendor/Contractor Mgmt.

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□ Capital Improvements

Material

Facility

□ Equipment Specification

PROFESSIONAL EXPERIENCE SIEMENS ENERGY & AUTOMATION (Full-Time Position) 1/2007 – 4/2009 (Manufacturing electrical breaker boxes) – Bellefontaine, OH (Manufacturing Engineer, Transition Team): • Project plan and coordinate duplication of large pieces of equipment along several production lines (12ton presses, spinner rivet machines, rivet machines, spot welding lines, etc.) for eventual operations move to Mexico; determine equipment needs for new manufacturing site. • Process items to be quoted: Write equipment specifications, determine vendor qualification, vendor selection. • Lead and plan relocation of production lines to international location – Monterrey Mexico. INDEPENDENT PROJECT MANAGER (Direct Contract) 2/2005 – 12/ 2006 Providing project engineering management services via third party contracts to major manufacturers/distributors. -PARKER HANNIFIN (manufacturing industrial hydraulics) – Marysville, Ohio (LEAN Implementer): Provide LEAN engineering support in Kaizen events developed for test, assembly and CNC machinery lines. Completed lean transformation in assembly from gang flow assembly to one-piece flow. Established Tugger route and all mechanical means to complete operation. Value stream mapping for products (current vs. future state). Time study analysis of work cells, presenting results through lean charts. -DELL INC. (computer distribution center) – Cincinnati, Ohio (Inventory Control/ Supply Chain Mgr): Supervised 38 hourly staff personnel to inventory and audit bulk computer parts inventory in 400K SQFT DC. • Provided management with consulting service to improve inventory control, warehouse receiving, order picking, and shipping. -GOODYEAR TIRE & RUBBER COMPANY (manufacturing automotive/industrial belts) – Marysville, Ohio (SAP Implementation): • In a contract assignment, was selected by management to direct 3 industrial engineers to establish labor standards and manning requirements for plant’s rubber products processing equipment that was to support plants new SAP system. Worked with SAP team to supply needed data input for new SAP system.

John A. Zacharias

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GREIF BROTHERS CORP. (manufacturing steel, fiber, plastic container products) – Delaware, Ohio 2000 - 2004 GLOBAL SUPPLY CHAIN MANAGER: Reduce material costs for steel drum product lines. ( 2004) • Established total cost of ownership (TCO) for drum products. • Analyzed cost for outsourcing component parts. • Developed bid process/vendor selections for outsourcing and national steel scrap agreement. • Annual cost savings achieved in first three months: over $2M CORE LEADER - LEAN MANUFACTURING: One of eight core leaders company-wide selected to implement a corporate initiative for LEAN manufacturing implementation at specific plants. ( 2003 – 2004) • Led first transformation team to achieve $1.25 M savings in operational changes. • Instructor for Excellence Academy (LEAN Manufacturing), presenting course materials to plant managers and team leaders and developing additional “hands-on” training to enhance prepared material. CORPORATE INDUSTRIAL ENGINEER: Supporting all industrial engineering needs for fifty-eight plants nationwide, manufacturing container products. ( 2000 – 2003) • Directed development of production standards, including equipment rates and crewing, for 60% of company plants to support new BaaN business system. GI PLASTEK (manufacturing plastic injection molded/gas-assist components) – Marysville, Ohio 1997 – 2000 INDUSTRIAL ENGINEER: Responsible for all industrial engineering activities at three facilities providing custom components to various OEM customers (Honda-Automotive, John Deere, Sony, AT&T, and USPS). • Developed specifications, and directed procurement and installation for (2) 2300 ton Mitsubishi horizontal injection molding presses. • Developed justification for and directed installation of two pick-robots – annual operational savings of $240,000. • Implemented and directed Continuous Process Improvement projects, including several organized Kaizen events. • Director of Safety overseeing EPA/ OSHA/ MSDS compliance. TRANSTECH CONSULTING (distribution consulting) – Columbus, Ohio 1995 – 1996 PROJECT MANAGER: Managed multiple projects in distribution engineering, servicing a broad client base in various industries. • Completed data feasibility studies including data analysis of client’s business records to determine customer order profile, SKU movement, location analysis, warehouse size and equipment needs. • Planned automated material handling operations and material flow (within a building and carrier routings to satellite locations) for order processing and completed related equipment specifications and vendor analysis. • Directed project installations and startups.

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WESTERN PUBLISHING (distribution center: media) – Crawfordsville, Indiana 1993 – 1995 CORPORATE DISTRIBUTION ENGINEER: Directed all engineering activities at 400,000 square foot distribution center. Completed renovations and facility startup. Managed total projects in area of facility improvements, material handling operations and product flow for current and projected volumes. • Achieved over $400,000 annual savings through operations improvements in first 18 months. Facilitated group planning with area managers and lead personnel in developing new/improved processing systems. Operations and facility management to support warehouse manager. BAUSCH & LOMB (new distribution center: contact lens/pharmaceutical) – Rochester, New York 1992 – 1993 PROJECT MANAGER (direct contract): Coordinated $1.8M project for automated warehousing/distribution system in new facility (Lynchburg, Virginia). Directed efforts for designing and implementing new material

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handling storage and order-filling system and new warehouse management system (WMS). Completed capacity and material flow analysis that was latter approved by upper management. Developed WMS functionality specification to support plant ISO-9000 qualification and was approved by IT staff. Directed on-site material handling system & WMS software/hardware system installation - on time and within budget. MOBIL CHEMICAL (Plastics Division - manufacturing polyethylene, polystyrene, and foam products) – Rochester, New York

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1989 – 1992 PROJECT ENGINEER: Team member of Central Engineering Technical Center servicing 12 North American plants. Managed multiple projects in process improvements, system engineering (plant expansion and modernization, product flow), labor utilization, new product/process development and material handling operations. Provided support for development of and accounted for project budgets, schedules and strategies. GOODYEAR TIRE & RUBBER COMPANY (manufacturing automotive/industrial hoses/belts) – Lincoln, Nebraska

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1985 – 1989 INDUSTRIAL ENGINEER: 12-month accelerated manufacturing management team assignment with rotations in production supervision, quality control and training, operations process, safety management, and rubber technology. Engineer on a 13-member business team directing automotive & industrial hose manufacturing (extrusion, rubber injection molding, blow molding, and robotic cell operations). Designed and implemented production process and layout. Developed and evaluated production levels and efficiency studies.

1984

EDUCATION Bachelor of Science, Industrial Technology Southeast Missouri State University

Cape Girardeau, Missouri