Ben Hopkins 🦺 The Warehouse Underground

REAL talk for warehouse, DC, & FC professionals of all levels around the globe!

Monthly responsibilities include sole responsibility for all aspects for traditional warehouse and distribution of a 200+ employee organization with 4,500 unique SKUs, average on hand inventory levels of 3.5M pieces, 2 separate warehouse facilities greater than 100,000 square feet, a $3M yearly operational budget, and yearly inbound/outbound volume approaching 16 million combined units serving thousands of BTB and BTC customers nationwide and internationally. Additionally, responsibilities include oversight of an embroidery and special service operation producing 200,000+ embroidered garments per year. Primary duties include direct and sole responsibility for all faces of organizational distribution strategies including safety and compliance programs, personnel, salaried manager(s) performance metrics and development, compensation plans, bonus program strategies, utilization of seasonal and temporary workforce, labor forecasting/budgeting, monthly operational execution and integration with all business owners to ensure all company growth and profitability goals achieved.

Sunex Tools International/Professional Tool Products, Travelers Rest, SC. - Drove an 18% overall reduction in cost per unit shipped while sales enjoyed a 15% increase in revenue and 9% increase in unit volume from prior year with a $2M operational labor budget including on boarding distribution of well-known e-commerce customer base (Amazon.com, HomeDepot.com, OReillyauto.com). - Developed, installed, and tracked 21 key performance indicators previously unknown to the organization and achieved above 90% in all areas increasing the bottom-line company margins by 2% from previous year. - Recruited leadership talent and local hourly talent to design and stand up an internal ICQA (Inventory Control & Quality Control) Department from scratch. Achieved a steady state customer facing performance metric of greater than 99% shipping accuracy by unit, 99% on time shipment compliance with over 5 million units shipped in 2016-2017. - Implemented multiple safety measures that resulted in only 1 loss time incident for 2016-2017 including Employee Safety Committee, Employee Safety Save Program, equipment operator safety awareness/training programs, monthly safety awareness training, & hired outside consultant that helped achieve 100% compliance on any OSHA specific safety requirements. - Implemented the company’s first ever Gemba Walk program. The program increased employee engagement, uncovered hundreds of small gains that added up to big operational wins, improved communication flow in a formalized manner, and allowed for employee development at the manager and floor associate level. - Led an internal distribution Kaizen targeting inventory space utilization and product flow location which contributed to up to 24% increases in space utilization and an overall reduction in order turn time by 4 hours. Also, was partially responsible for the warehouse reduced need for equipment rentals which saved $1K per month.

- Led GSP1 Non-Sort Record Peak Week to record setting productivity numbers, managed / led over 150 hourly associates per day. Week totals 12/12 48,994 units, throughput 30.78, 111% to plan. 12/13 49,820 units, throughput 32.26, 110% to plan, 12/14 46,903, throughput 32.5, 111% to plan. - Strategized and executed consolidation strategy for the Fulfillment Center leading to 20% higher space utilization and 40% higher empty bins counts. - Led standard work implementation in Inbound by developing standard work check sheets for the managers, hourly leader process assistants and processes guides. - First to implement process at GSP1 of simultaneous unloading of 3 Fulfillment by Amazon parcel trucks with over 1,200 boxes in each. Lead to reduction in Service Level Agreement misses of 27%, while maintaining problem piles below acceptable levels, and allowed 2,500 extra units to be received and processed per shift. - Designed layout and process of detailed plan for offloading and stowing 30,380 units of Reactive Arc Transship (Very Hot Quick Turn!) volume and set record for GSP1 single shift transshipment turn performance. Utilized visual diagrams to orchestrate. First trial run performed at 107% to plan with zero safety incidents. - Implemented leadership development plans for GSP1 hourly associates. Directly mentored and coached 3 hourly associates selected for and promoted to Process Assistance roles and 2 Process Assistances chosen for Area Manager interviews. - Led GSP Outbound performance to record breaking volume shipped during Amazon's first every Prime Day at 52,000 units shipped in one 12 hour shift including large variation in product dimension from toothbrushes to 70 inch televisions. - Managed a seasonal temporary workforce of 170 employees specifically designed to handle volume spike and trained in short time frame then strategically handled the employee draw down to achieve proper staffing post Peak volume surge.

Developed and scheduled training and operational activities for 400+ personnel and 70+ aircraft worth $2.8B+ while directly managing training, evaluation, discipline, and career progression of 10 personnel. Collaborated with Human Resources, Finance, Maintenance, Logistics, and Operations units to create, execute, and conduct After Action Reviews of critical operational and support programs. Utilized vast business and operational planning skills to design cost-effective programs that maximize potential of operations personnel and fully exploit capabilities of high-value operational equipment. Managed 12.5K training obligations and scheduling for 80 operational teams, ensuring all personnel remained compliant with requirements and pilot qualifications in rigorous, highly complex training program with $360M annual budget. Collaborated with Department of Defense and international forces to plan and execute multibillion-dollar global operations. Reviewed statistics, and conducted data analysis in performing After Action Reviews of operations and training programs; identify areas for improvement and revise programs to incorporate necessary changes. Initiated, drafted, and executed innovative operational and maintenance upgrade program to high-value equipment to implement new equipment features on $40M fighter aircraft, ensuring successful international operations that maximized new capabilities. Employed keen strategic thinking to standardize critical planning system procedures, reducing operational planning by 50%. Deployed twice to Afghanistan and served as key liaison with external units and higher headquarters in executing daily acquisitions and delivery of crucial supplies daily to F-15E aircraft supporting Operation Enduring Freedom. Recognized as superior performer by Higher Headquarters inspection team for achieving zero discrepancies during meticulous inspection of all operational, training and support programs

Leader of 2 officer and 3 AF enlisted member shop responsible for daily flight scheduling of 70+ F-15E aircraft valued at $40M each. Strategic planning and accounting of Wing's $360M Flying Hour Program. Manager of FY11 Flying Hour Program (third largest in Air Combat Command) and one of only 4 units Air Force wide to complete flying hour contract at 100% efficiency.

Certified F-15E flight instructor. Responsible for training, evaluating, mentoring newest F-15E aircrew. 200+ F-15E flight hours solely devoted to development of junior officers.

Leader of 5 officer shop directly responsible for squadron computer system and mission planning software upgrades. Integrated with higher headquarters level directives ensuring standardization of F-15E mission planning standards. Implemented operational security plans to safeguard classified F-15E mission planning software programs.

Leader of 3 officer shop responsible for ensuring squadron compliance with 9th Air Force Instructions. Developed, implemented and tracked training plan/requirements for 70+ aircrew for daily flying operations and Operation Enduring Freedom. Work directly resulted in being named Air Combat Command Unit Compliance Inspection Superior Performer.

Managed 6 F-15E aircrew. Drafted performance feedback reports and ensured appropriate supervision for upgrade training.

Graduate and awarded #1 base of choice for follow on assignment. FTU consisted of 150+ hours of F-15E academic instruction and 150+ hours of F-15E flight time.