RICK RALSTON

1102 McClurg Drive, Batavia, IL 60510 630.746.1243 rr10d9e50@westpost.net

OPERATIONS MANAGEMENT / PLANT MANAGEMENT

~ 15+ years of success leading, people, projects, and resources while containing
cost & enhancing profits ~
Diligent, quality focused, and personable Operations Manager and Plant Manager w
ho is well versed in all facets of production and manufacturing operations, pers
onnel management, and safety standards within fast-paced, time sensitive environ
ments. Hands-on leader who is valued and well respected by staff at all levels f
rom the plant floor to executive management. Adept in planning, scheduling, and
process improvement to advance business and profits. Motivating and inspiring to
others with a contagious enthusiasm and a high degree of integrity. Established
reputation for quality, satisfaction, and results.
Proven areas of expertise include:
* Production & Manufacturing * Operations Management * Project & Program Man
agement
* Multi-Site Management * Kaizen, 5S & Lean Principles * P&L Management
* Shipping & Logistics * Materials Management * Staff Training & Developme
nt
* Team Building & Motivation * Recording & Reporting * Client Relations/Cust
omer Service
* Cost Controls * Planning & Scheduling * Bidding & Costing
* Communications & Presentations * Problem Solving * Revenue Enhancement
PROFESSIONAL EXPERIENCE
SLEEP INNOVATIONS/ADVANCED URETHANE TECHNOLOGIES, WEST CHICAGO, IL (5/2009 10/2
010)
PLANT MANAGER
Managed total staff of 300+ for 3 shifts and 3 building locations that included
salaried management team of 13. Provided operational oversight for all business
functions and routines at a facility that processed 160M in BDFT foam and genera
ted $90M+ annually. Communicated with and reported frequently to EVP of Manufact
uring within corporate office at West Long Branch, NJ. Held full P&L accountabi
lity for multi-site operations, created/managed yearly budgets, and facilitated
capital expenditures and projects. This included, but was not limited to, safety
program management, environmental compliance and improvement, green initiatives
, supply chain management, maintenance project management, PM programs, logistic
s coordination, and outbound management. Established and measured plant metrics,
applied Lean principles, and spearheaded culture transformation for continuous
process improvement.
Key Achievements:
Assessed daily operations and productivity, hired and trained additional staff
as warranted to meet needs of business, and ensured highest regard to efficiency
and safety at multi-sites.
Played a key role in creation/implementation of many green technologies that en
hanced operations, reduced cost, and supported environmentally friendly programs
.
Led from a position of strength, focus, and results while maintaining high visi
bility at all plant locations.
SLEEP INNOVATIONS/ADVANCED INNOVATIONS CENTRAL, ELKHART, IN (2/2004 5/2009)
PLANT MANAGER
Managed staff of 240+ and management team of 13 for 3 shifts at plant that proce
ssed BDFT foam volume of 100M yearly and generated R120M in sales. Accountable f
or all daily operations of the manufacturing facility and 3 offsite warehouses.
Worked closely with executive management at corporate in West Long Branch, NJ on
all business plans, projects, and routines.
Key Achievements:
Promoted 5S culture/philosophy that included an assessment program well receive
d by hourly ranks.
Set-up and applied the plants first PM Program, as well as multiple Kanban inve
ntory replenishment systems that reduced stock outs in both finished goods and r
aw materials.
Established and managed Quality Department with guideline to become ISO complia
nt, capped off by passing two 3rd party ISO compliancy audits, and the Safety an
d Continuous Improvement Committees.
RICK RALSTON ~ PAGE TWO
Directed 6 new equipment installations that resulted in major line layout chang
es for greater work efficiency.
Managed 3 continuous years of phenomenal volume growth of 70%, 35%, and 27% res
pectively.
Trained and mentored all leads and supervisory associates in Lean 101 technique
s.
Spearheaded major culture shift amongst all employee groups that greatly enhanc
ed morale, encouraged staff participation in company plans at all levels, and re
sulted in an upbeat, safe, and profitable operation.
Awarded companys annual Plant Safety Award on 3 occasions.
CARPENTER COMPANY, ELKHART, IN (7/1998 2/2004)
ASSISTANT PLANT MANAGER
Managed staff of 300+ hourly, 27 salaried managers/supervisors, and provided ope
rational oversight for a 1M square foot building that generated over $100M in an
nual sales. Planned, scheduled, and coordinated all business programs, functions
, and routines for all departments and divisions. Worked closely with sales forc
e and customers on quality and logistical issues for optimum production and clie
nt satisfaction. Defined, applied, and managed operational goals and objectives
for Safety, Quality, Maintenance, Continuous Improvement, and Key Indicators.
Key Achievements:
Hired initially in a management training role and rapidly promoted to Assistant
Plant Manager for exemplary job performance and work contributions.
Created and managed Kaizen Program that grew uptime 15%, throughput 40%, and ma
terial usage 8%.
Developed and implemented a Direct Flow Scheduling Program that promoted JIT in
ventory and reduced stock levels by 50% to 70%.
Recognized by corporate for setting 4 major company records for production outp
ut.
Supported establishment and introduction of Preventative Maintenance Program th
at enhanced machinery operations and servicing.
Contributed to multiple layout changes, new equipment start-ups, and new produc
t start-ups.
QUALEX, SOUTH BEND, IN (3/1998 7/1998)
PRODUCTION SUPERVISOR
Managed staff of 30 production workers and provided operational oversight for da
ily output within the Paper Department. Planned, coordinated, and facilitated wo
rk assignments and schedules. Supervised quality control of all products prior t
o packaging and disbursement.
Served as a liaison with staff from other departments on production issues for
optimum efficiency and output.
EARLY CAREER as a Zone Manager, Lowes Home Centers(1994 -1998).
EDUCATION AND TRAINING
B.A. in Business Management and Administration
Emphasis in Entrepreneurship, Marketing & Management Theory
Indiana University, South Bend, IN
Professional Development:
Coveys Motivating Your Management Team
Dale Carnegie, How to Win Friends and Influence People
Critical Skills for Supervisors I & II, Reinhart Technical Center
2-Lean Manufacturing and 5S Seminars
Value Stream Mapping
APICS CPIM and CPSC Certification Programs
PROFESSIONAL AFFILIATIONS
Valley Industrial Association, Member of Board of Directors
Valley Industrial Association, Career Awareness Committee Member