David Elliott

Plant Manager for a high quality, high volume direct marketing printer and services company.  FCL employs sheetfed, full & half web offset and digital printing to provide a variety of direct mail products to Fortune 1000 companies and other direct marketing providers. Services also include full service bindery, mail file prep, off line imaging, mailing services and fulfillment.

Initial assignment with FCL was as a consultant identifying and implementing operations improvement and cost reduction opportunities.

Security printer specializing in Vital Records, tax stamps & brand protection solutions.   2nd phase start up, investor owned. 

Responsibility for all manufacturing departments managing 50 FTE and 5 supervisory employees.  Print and finishing technologies include UV Flexographic and intaglio printing; web inline and off line variable imaging; and standard finishing operations.  Report to CEO.

ACCOMPLISHMENTS

● Sourced and installed machine vision system to 100% inspect secure documents for print defects, replacing human examination.  System now fully operational resulting in reduction of 8 FTE’s and payback in less than 7 months.

● Team member of ISO 9001 implementation for brand protection business, including developing work procedures.

Responsibility for all manufacturing and distribution operations for a high quality specialty publication, phone book and directory printer.  Manufacturing operations include web coldset printing, saddle stitching, inserting and mail addressing.  Reported to President.

ACCOMPLISHMENTS

● Teamed with Purchasing & Scheduling functions to reduce paper inventory value by 40% from 2012 levels.

● Working directly with press crews, initiated make ready & running process changes, reducing waste 25% across all product volumes.

P&L responsibility for Manufacturing, Engineering, Accountability, Security, and Distribution operations for a USPS postage stamp (PSA), brand protection label, secure document and stamped envelope producer.  Managed 160 staff and hourly employees at two locations.  Manufacturing processes include UV web offset, flexo coating, offline die cutting, offline coiling, envelope printing, ink jet personalization, machine vision inspection, finishing and secure fulfillment.  Reported to President.

ACCOMPLISHMENTS

• Renegotiated contract with vendor and implemented rigorous recycling effort for waste paper removal, resulting in 40%  cost reduction.
• Successful 2010 integration of web envelope converting  (operated by partner )  into Ashton Potter facility, reducing base cost 12%.
• Managed 2008 start up of 2nd facility for the manufacture and personalization of secure stamped envelopes. Assisted with lease terms, managed capital plan to procure production equipment & facility build out, web based fulfillment software and start up staffing.Completed on time and in budget.
• Achieved 10% waste reduction, machine performance of 113% to budget and reduction in FTE’s in 2007.
• 2005 Cost Savings plan resulted in a total documented reduction of manufacturing costs in excess of $250,000.
• In 2007 & 2010, coordinated sourcing, product evaluation and negotiated contract with successful vendor for supply of printing inks, resulting in limited price increases and initiation of annual dollar volume based discounts  exceeding 10%.
• Managed installation and start up of  multi million dollar equipment and technology purchases to achieve manufacturing capacities required by USPS contract.  Included 10 color UV web offset press with machine vision and several unique finishing capabilities.

U.S. subsidiary of American Bank Note Corp., a $220 million international commercial and security printer.

P&L responsibility for Tennessee division manufacturing secure government documents, commercial gift certificates, vital records, print management and secure distribution.  Managed 130 employees at two locations in production, QA, distribution, IT, security, customer service and maintenance.  Processes include UV web offset, sheet fed, digital, intaglio, mechanical numbering, roll to roll collating and finishing operations. Reported to President.

ACCOMPLISHMENTS

• Managed identification, purchase and relocation of 10 color UV web press to improve efficiency of current product lines and position company for entrance into additional commercial printing markets.  Project completed under budget.
• Directed all activities, including IT, staffing & capital, for entrance into new market of print management for select international organizations.  First 6 months contribution of 35% vs. 10% forecast.
• Directed restructuring of 50% of plant floor to accommodate introduction of new workflows.

$60 million commercial & specialty printer and related services.  Division of Quebecor World, a $6.2 billion dollar publicly traded international printer.  (Formerly Dittler Bros. Inc., until 1999 acquisition by Quebecor ).

Responsible for the manufacture of direct mail, specialty labels, timetables & directories, high value promotional games, inserts, scratch off lottery tickets and commercial printing.  Managed 220+ hourly and 12 managers & supervisors. Printing processes included web offset, sheet fed, flexography & solvent gravure printing, web in-line press imaging & finishing.  Managed numerous bindery and finishing processes including onserting, off line imaging, sheet collation, perfect binding & stitching, and roll to roll offline finishing.  Reported to division Vice President.

ACCOMPLISHMENTS

• Project member for installation & start up of unique dual web offline, including ink jet imaging.  Supported direct mail market.
• Managed R&D and production testing to develop new lottery ticket substrate, moving  customers to improved product.  Realized cost savings in excess $1 million annually.
• Achieved ISO 9001 certification for both Lottery and Commercial print businesses.
• Manufacturing consultant and trainer on team implementing MIS platform for Quebecor Direct group,  installed at 5 locations. 
• Oakwood plant awarded Quebecor President's Award for safest mid-size plant in 2000 (100+ locations).

Production & Bindery Mgr.          1998 -- 2000         

Plant Production Supervisor        1995 – 1998

$2 billion producer of manufactured housing, recreational vehicles and travel trailers, making Fleetwood the No. 1 home builder in the nation.

Trained via a rigorous "hands on" program to gain competency in all production departments and processes required to assemble manufactured homes meeting strict multi-state building codes and the highest quality requirements.  Upon completion of training, assignment as Production Manager at a Fleetwood assembly plant.

Production-Manager-in-Training   Douglas, GA

Contract Engineer   TX

$75 million specialty printer & related services including direct mail, promotional games, airline timetables, hotel/motel directories, instant win lottery tickets, postage stamps and commercial printing.

P&L responsibility for Dittler subsidiary for the manufacture of specialty printing inks and coatings, supporting commercial, lottery and specialty product markets.  Managed 25 employees in production, quality assurance,  budgeting, material procurement, product development, outside sales and environmental compliance. Reported to Vice President, Moreno Press Division.

ACCOMPLISHMENTS

• Reduced  hazardous waste costs $19,000 annually through aggressive rework of surplus inks and coatings.
• Implemented cost reduction actions resulting in $260,000 savings from FY1993 budget
• Coordinated paper testing for compliance with strict Postal Service material quality requirements, using database developed with vendor to reduce testing costs 28% for 2nd and subsequent orders.
• Directed R & D activities for improvement of instant lottery ticket security coating,  strengthening Dittler's market position with $5 million annual customer.

Industrial / Project Engineer    1990 – 1991             

Manufacturing Supervisor        1989 - 1990

Engineering