Manufacturing Operations Consultant

Technical Consultant #2408

Operational excellence services in capital management, due diligence, organizational design and industrial safety improvements, manufacturing and operations efficiency.
Global operational manufacturing, supply chain, finance, engineering, continuous improvement and EHS.
Building high performing, cross functional teams, and cultivating effective working relationships.
Project management
Continuous improvement
International business
Industrial safety
Cost control
Collaborative team building

Undisclosed Company, Principal, Present

Providing capital project management, due diligence, manufacturing and operations efficiency, organizational design and industrial safety improvements.
Pharmaceutical vial inspection efficiency improvement process to double productivity with a payback.
Integrate a zero-emission material transfer system for potent compound manufacturing designed for improved EHS conditions in manufacturing.
Leading capital projects for a client that include a 50,000 SF building sprinkler system and lobby refurbishment.
Managing and sourcing a pharmaceutical compounding process to secure significant additional in client revenue.

Johnson Matthey, Wayne, PA, Director, 2011 - 2017

Global Operations Director, 2015 - 2017

Reporting to the Division President with operational responsibility for (9) global manufacturing sites employing over 1000.
Revenue base of $700 million, that included an operations cost base of $280 million in both union and non-union facilities.
Established a matrixed global operations team from bolt-on acquisitions to maximize divisional efficiencies.
Led reduction of working capital by $21 million over 12 months period through new supply chain alignment project, inventory turns analysis and redefining stock replenishment levels.
Drove global manufacturing asset base review to improve OEE and support changes in business strategy.
Delivered $8 million of continuous improvement savings across global fixed and variable costs through energy reduction programs, re-deployment of labor and six sigma efficiencies resulting in a 4.5% savings against budget.

Group Operational Excellence Director, 2011-2015

Led reduction of global LTIIR (Lost Time Injury Incident Rate), or and (TRIIR Total Recordable Incident Rate) 42% over 18-month period, through targeted global training programs, internal audits and improved visibility of metrics.
Re-aligned global occupational health program to align with geographical constraints and laws governing employee health and wellness.
Oversaw energy reduction of 4.1% across the company portfolio with global sustainability initiatives and site evaluations.
Designed and implemented global program to drive manufacturing efficiency across all divisions targeting areas in people, efficiency, technology and engineering.
Realized improvement in company cost/sales ratio of 2.8% across all businesses.
Advanced Manufacturing Excellence program with targeted lean initiatives and executive level training.

North American Operations, West Deptford, NJ, Director, 2003 - 2011

Director - Chemicals, Catalysts and Refining

Direct performance for two precious metal chemical plants (West Deptford, NJ; Sevierville, TN) with over 300 union and non-union employees.
Managed over $80 million operating budgets, $3 billion in working capital, environmental health and safety compliance, labor contract negotiations, sustainability initiatives, new plant development implementation and new business commercialization projects.
Led design, construction and start-up of new chemicals manufacturing plant in Shanghai, China
Drove the development and implementation of a new refining process resulting in $14 million of new revenue.

Additional Experience

Environmental Tectonics Inc., Southampton PA, 1999 - 2000

Johnson Matthey Environmental Products, Devon, PA, 1996 - 1999

Johnson Matthey Emission Control Technologies, Wayne, PA, 1992 - 1996

Handy & Harman Tube Co., Norristown, PA, 1989 - 1992

ALP Lighting Products, Pennsauken, NJ, 1987 -1989

Credentials

Executive Program in Corporate Strategy- University of Chicago, Booth School of Business
Executive Leadership Development- London Business School, London England
Kaizen Foundations - The Kaizen Institute, Japan