JOSHUA MANOTAS
Natchitoches
Summary
Highly skilled and experienced Manufacturing, Process, and Quality Executive with a proven track record of success. Leads large multidisciplinary teams in complex projects to transform operations, improve the customer experience, and drive significant bottom-line results. Six Sigma Black Belt and Lean Management expert, skilled at dissecting issues and strategically driving efficiency within the business. Achieves positive results in quality and productivity through innovative technology and system automation. Drives high productivity operations with 100% safety compliance. Trusted business partner known for consistently leading projects to completion.
Overview
25
25
years of professional experience
1
1
Certification
Work History
Senior Manager, Process Improvement, Master Black Belt
Smurfit Westrock
01.2024 - Current
- Company Overview: A global leader in sustainable paper and packaging operating in 40 countries with over 500 converting facilities and 62 paper mills
- Managed the operational transformation of our North American Mill division
- Driving enterprise-wide productivity and financial performance improvements
- Direct oversight and responsibility for the implementation of the Smurfit Westrock Daily Management System (DMS) across 10 manufacturing facilities throughout the United States
- Targeted specific opportunities for facilities based on OEE and Cost Take Out metrics
- Assisted the region in achieving cost per ton and EBITDA targets throughout the fiscal year
- Developed strong, cross-functional partnerships to accelerate performance and cost improvements
- Partnered with facilities to develop and implement reliability programs
Chief Operating Officer & Chief Financial Officer
Bear Handed Designs LLC
06.2023 - Current
- Led the development and monitoring of key performance indicators (KPIs) to track financial performance and identify areas for improvement
- Managed all aspects of financial planning, budgeting, forecasting, and reporting, ensuring accurate and timely financial information for strategic decision-making.
- Developed and executed strategic operational plans, resulting in a 37% increase in production efficiency and a 24% reduction in operational costs.
- Spearheaded the integration of new technologies and systems to enhance operational efficiency and drive innovation.
- Developed and managed the company's supply chain, ensuring on-time delivery and cost-effective procurement.
- Drove a culture of continuous improvement, fostering a collaborative and high-performing work environment.
Manufacturing Excellence Manager
International Paper
02.2021 - 01.2024
- Company Overview: A leading global supplier of renewable fiber-based products with 38K global employees and $21.2B in net annual sales
- Promoted to spearhead the Finished Products Manufacturing Excellence program including year-over-year (YOY) continuous improvement of safety, quality, productivity, reliability, and cost reduction
- Train/coach Lean Six Sigma company-wide while leading a team of 4 direct reports and developing/mentoring Process Engineers
- Construct the annual strategic plan to drive multiple concurrent cost reduction and lean manufacturing projects
- Liaise with all levels of the organization to conduct project identification and effective execution within the business units
- Introduced SOPs to guide issue analysis, implemented KPIs, and leveraged advanced data analysis to drive issue resolution
- Increased facility productivity by more than $16M per year with zero safety recordables during tenure
- Saved $2.5M and reduced 48 hours of equipment downtime with an operations delivery improvement project
- Captured $2.4M in savings through leadership of a $4.5M capital project from ideology to implementation
- Facilitated and coached sessions for Toyota KATA, Lean Principles, DMAIC, 5S, Kaizen, VSM, PDCA, Standard Work, and many other Lean Six Sigma tools
Area Operations Manager
International Paper
01.2018 - 02.2021
- Promoted to lead 8 direct reports and a team of 46 crew members and contractors with responsibility for safe work practices and environmental stewardship of the mill
- Managed the production model and balanced recovery chemical volumes, pulp volumes, and paper volumes at optimum levels
- Cultivated a supportive work environment while enforcing company policies and procedures
- Performed new employee onboarding along with performance reviews and coaching
- Earned the Chairman's Award for leading Recycle from underperforming to a top-performing and highly reliable area
- Achieved zero recordable incidents in the role and 100% participation in the monthly safety program and initiatives
- Delivered at or below budget spending every year while leading numerous capital projects to improve process performance and reliability of the mill
- Contributed directly to strategic planning with senior leadership
- Generated $450K in annual savings with a lean project to reduce the environmental impact of process waste streams to the effluent system
- Reduced an estimated $196K/year in purchased electricity through a lean project to decrease process variation
Operations Maintenance Coordinator
International Paper
08.2016 - 12.2017
- Coordinated between the Operations and Maintenance teams to achieve improved process reliability, safety, and productivity through Manufacturing Workflow Systems (MWS) and daily use of SAP
- Managed the monthly budget with the Area Process Manager (APM) to remain within budget and scheduling parameters
- Served as the interim APM managing both the Recycle process and all Operations team members
- Created and implemented Basic Care system and training for operators to reduce equipment repair expenses
- Participated in 5-year capital plan development
Account Manager & Safety Coordinator
Nalco, An Ecolab Company
01.2014 - 07.2016
- Company Overview: A global leader in water and process management solutions with a presence at more than 100K customer sites
- Promoted as the Site Supervisor, specialty chemical Account Manager, and Safety Coordinator for 15+ Sales employees
- Owned multiple large specialty chemical accounts in the pulp and paper industry with multimillion-dollar annual values
- Collaborated with customers, internal departments, and outside agencies to execute strategic projects
- Interfaced and communicated at an executive level internally and externally
- Increased account growth by 2.5% YoY and played a role in securing one of the company’s largest accounts
- Identified and realized operational cost savings opportunities of $100K+ per year
- Conducted site safety audits and maintained a perfect safety record for 15 district employees
District Sales Representative
Nalco, An Ecolab Company
03.2010 - 01.2014
- Served as Site Supervisor and Manager of a paper mill specialty chemical account valued at $3.5M annually
- Developed and tracked data with SAP and various Microsoft Office databases
- Spurred YoY account growth of 2% for 5 years
- Acted as District Safety Coordinator for 4 years with zero safety incidents or accidents
Helicopter Flight Instructor
United States Army
08.2000 - 03.2010
- Trained and evaluated UH-60 helicopter crew chiefs on Department of the Army (DA) standards, flight safety, and skills
- Carried responsibility for 35 employees’ training, combat readiness, and scheduling in sometimes high-stress environments
Education
Master of Business Administration -
Sam Houston State University
Huntsville, TX01-2026
Bachelor of Science - Occupational Health & Safety
Columbia Southern University
Orange Beach, ALSkills
- Process Optimization Expertise
- Operational excellence
- Efficiency Improvement
- Continuous improvement
- Effective Strategic Communication
- Project management
- Daily Management Systems
- Lean manufacturing and operations
- Root analysis
- Kaizen facilitation
- Data Analysis Expertise
- Value stream mapping
- Strategic planning
- Budget administration
- Influencing and negotiating
- Financial management
Certification
- Lean Six Sigma Black Belt Certification
- KT Analytical Troubleshooting Certification
- Lean Six Sigma Green Belt Certification
- Lean Six Sigma Yellow Belt Certification
- Federal Aviation Administration - Airframe & Power Plant License
- United States Army - Graduated Leadership Development Course
Affiliations
- Member, Pi Kappa Phi Fraternity
- Veterans of Foreign Wars
- Disabled American Veterans
Awards
- Chairman's Award, International Paper
- Paper Sales District MVP Award, Nalco
- Paper Sales Achievement Award, Nalco
- Sikorsky Rescue Award, U.S. Army
- Army Chief of Staff Excellence Award, U.S. Army
- Sikorsky Maintenance Excellence Award, U.S. Army
Timeline
Senior Manager, Process Improvement, Master Black Belt
Smurfit Westrock
01.2024 - Current
Chief Operating Officer & Chief Financial Officer
Bear Handed Designs LLC
06.2023 - Current
Manufacturing Excellence Manager
International Paper
02.2021 - 01.2024
Area Operations Manager
International Paper
01.2018 - 02.2021
Operations Maintenance Coordinator
International Paper
08.2016 - 12.2017
Account Manager & Safety Coordinator
Nalco, An Ecolab Company
01.2014 - 07.2016
District Sales Representative
Nalco, An Ecolab Company
03.2010 - 01.2014
Helicopter Flight Instructor
United States Army
08.2000 - 03.2010
Bachelor of Science - Occupational Health & Safety
Columbia Southern University
Master of Business Administration -
Sam Houston State University
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