1John A.

Zacharias
313 West 7th Street Marysville, Ohio 43040
Cell: 937-243-8469 Home: 937-642-5588
Email: jzachari@columbus.rr.com
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 □ Strategic Planning □ Material
Handling
□ LEAN Manufacturing □ Budgeting/Forecasting □ Warehouse System
Design
□ SIX Sigma/ISO-9000 □ Cost Analysis – labor, supply chain □ Facility
Layout Design
□ Kaizen/Continuous Improvement □ Vendor/Contractor Mgmt. □
Installations/Start-ups
□ EPA/OSHA Compliance □ Capital Improvements □ 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 (12-
ton 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 Page 2

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.
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
 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

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

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.

EDUCATION
Bachelor of Science, Industrial Technology
1984
Southeast Missouri State University Cape Girardeau, Missouri