1. Douglas A. Kalvig
109 Dylan Drive, Unit 102 • Jamestown KY, USA 42629
M: (812) 767-4455 • plasticdak3@yahoo.com
Plant Manager | Tooling Manager | Senior Process Engineer
Dynamic and technically astute manager with record of energetic leadership in development in large and small
companies including Plant Start-ups, Plant Moves, and turnarounds. Expert in building multi-functional teams.
Consistently successful at delivering results by focusing on both immediate goals and long-term objectives. Achieve
breakthrough performance by combined expertise, New tool sampling, Proto-typing, Material selection and
understanding shrink, Direct customer contact, and relationships with material representatives to achieve, material
assistance and input, pricing, and alternative solutions that assist our customers in solving opportunities.
 New Tool Sampling, and process development and documentation
 Proto-type sampling, and process development and documentation
CAREER PROGRESSION
Bruss N.A., 600 Progress Blvd., Russell Springs, KY, 42642 8-2016 – Present
Plastics & Tooling Engineer, Master Molder.
I have 37 years of manufacturing experience. Currently working with a Bruss North America, a Major
Automotive Manufacturer, to design and build molds that fit Decoupled, scientific molding standards,
with Tooling and Production responsibilities.
To evaluate current tooling and repair and improve as necessary to meet Automotive standards.
To evaluate current, and future mold designs to assure quality and production rates can be obtained
and held.
* Injection Molding Professional, Engineering grades of material, multi core, insert molding,
automation, design for manufacturing, DOE, SPC, QS9000 Six Sigma, Scientific/decoupled molding
experience.
* I believe a company’s strength is its employees, and promoting within. A company needs a steady
flow of trained employees, internal training, develop a local Vo-tech, Internships, Certifications, to
build a workforce, keep balance and allow for growth. Training builds confidence, and creates a
competitive atmosphere in the workforce.
 Material and shrink identification  Team Building at all levels
 Toxicology and Material certification  Key Customer Relations, Negotiations, & Pricing Strategy
 Profit Optimization and budgeting  Growth Strategies: Penetrate, Extend, Diversify
 Strategic/Operational Planning & Execution  Reporting & Communications

2. F I R S T L A S T N A M E P a g e | 2
Decatur Mold Tool & Engineering, Inc - North Vernon, IN 47265,- 5/2002 – August 2016
Injection Molding, Tool Builder Manufacturer of steelparts and fabrications for Military, Proto-type tooling, engineering
and material selection with a state-of-the-art highly automated manufacturing equipment. Product development, working
with customers, and material suppliers to solve our customer’s issues. Low volume contract manufacturing, as bridge to
production tooling. Foreign Trade Zone, Engineering Staff in Shenzhen, China. Distribution center.
Process Engineer, FTZ Director, Licensed Customs Broker
Multi-task Manager, Scientific Molding Practices, Material Toxicity, Proto-Type Tooling and Molding development,
Material selection and ordering, electronic warehouse inventory system, and electronic scheduling systems. Developing
Foreign Trade Logistics, Conforming to Customs Laws, Entries per US Customs Regulations
• Proto-type development, bridge tool runs, and slowly moving into production – I took the concept,proved it to be the
single largest profit center. Took monthly revenues in sampling from $50,000 to over $300,000 and the results are still
growing
• Personally trained technicians on staff to new technologies, and assisted with molding issues.
• Developed Tooling review and mold ability review practices.
• Master Molder I Certification, Master Molder II Certification, Instructor Status
• Total profit & loss accountability for projects
• Developed The Foreign Trade Zone from Application to Activation, including C-TPAT, Customs Brokerage License
• Wrote U.S. Customs Binding Rulings for NAFTA status on imported tooling.
• Developed and licensed the trucking fleet allowing military and government transport – Bonding to allow Direct
Delivery
Plastic Products, - West Branch Iowa, - 10/2001 – 5/2002
Manufacturerof Injected Molded Parts, Amana Whirlpool.
Plant Manager
• Total plant transformation from injectable foam to an injection molding of thermoplastics facility and the plant start-up.
• Reviewed and negotiated contractor permits and agreements, local inspections.
• Personnel staffing, including hiring, firing, and developed training at every level to cross train and utilize former
employees, reviewing work histories. 120 employees, 24 injection molding machines
• Direct customer contact on quality, orders, delivery schedules and requirements.
• Hands on processing,process development, proto-typing and process documentation, working with customers directly.
• Personally trained technicians on staff to new technologies, and assisted with molding issues.
Nailite International, Miami, Florida, - 8/1997 - 1/2001
Injection Molded proprietary siding for homes. CustomHVLP paint lines, sold directly to distributers and contractors.
Plant Manager
Reported to the President and Director of Manufacturing. Plant move, and start-up,55,000 SF TO 124,000 SF, 3 shift –
100+ employees
• Reviewed and negotiated contractor permits and agreements, local inspections.
• Total plant control Injection Molding facility and paint line, including the plant start-up.
• Reviewed VOC laws, permitted and installed a Thermal Oxidizer to eliminate VOC issues generated from the paint
lines.
• Modernized, procedures developed for the paint line, booths and speed drying.
• Developed Kanban for automatically triggering production orders, gravity racking, to flagging shortages, increasing
inventory level turns 30 times.
• Drove growth, EBITDA: 18%, 24%, 25% growth, expecting in excess of 30% in 2001
• Hands on processing,process development, proto-typing and process documentation, working with customers directly.
• Personally trained technicians on staff to new technologies, and assisted with molding issues.

3. F I R S T L A S T N A M E P a g e | 3
Royal Plastics, - Mentor, Ohio, - 8/1990 - 1/1997
Injection Molded parts for Royal Appliance, Bendix, GO-JO industries, and assembly operations from sonic welding to hot
stamp and pad printing
Plant Manager
Reported to the President and Director of Manufacturing. Plant start-up,Ground breaking to full 3 shift operation, 100+
employees, 25 injection molding machines.
• Reviewed and negotiated contractor permits and agreements, local inspections.
• Total plant control Injection Molding facility, including the plant start-up.
• Staffing including hiring, firing, and training developed
• Direct customer contact on quality, orders and delivery schedules and requirements.
• Ground breaking to initial production 3 months.
• Developed a FAI lab and made it a profit center, and generated new customers while offsetting quality costs.
• Program management and quoting were all part of daily activities.
• Hands on processing,process development, proto-typing and process documentation, working with customers directly.
• Personally trained technicians on staff to new technologies, and assisted with molding issues.
Complex Tooling, - Boulder Co., - 5/1980 - 1/1990
Tool building, Injection molded parts for Cobe Laboratories, IBM, Hewlett Packard, McData Corp., assembly operations
including sonic welding, hot stamp and pad printing.
Entry Level to Production Manager in 3 years
Reported to the Director of Manufacturing. 25 injection molding machines. 120 employees
• Reviewed and developed 23 training programs for employees, for evaluation and internal promotions
• SPC at the press developed and taught
• Staffing including hiring, firing, and training I developed.
• Direct customer contact on quality, orders, delivery schedules and requirements.
• Developed a FAI lab and made it a profit center, and generated new customers while offsetting quality costs.
• Program management and quoting were all part of daily activities.
• Hands on processing,process development, proto-typing and process documentation, working with customers directly.
• Trained over 80% of the mold technicians on staff
EDUCATION
No Degree • University of Iowa – Iowa City, Iowa –
HOBBIES and INTERESTS
Golf • – Played since Jr High School
Bowling • - Not as often as I like
Fishing • Bass, Crappie, Pike