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Manufacturing Operations Consultant

Technical Consultant #2408


Expertise

  • 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

Experience

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

  • Process Simulation Division Manager

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

  • Product Specialist

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

  • Senior Project Engineer

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

  • Plant Engineer

ALP Lighting Products, Pennsauken, NJ, 1987 -1989

  • Manufacturing Engineer

Honors & Publications


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

Education

  • MBA Business Management, Penn State University, University Park, PA
  • B.S. Mechanical Engineering, Penn State University, University Park, PA
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