PLANT OPERATIONS MANAGER
Cost Control / Start-Up / FDA / OSHA / Metrics / QA & QC / Safety / RFT / Budgets / Productivity / Training / Lean Manufacturing / Employee Relations / Compliance / Six Sigma / Change Leader / ISO 14000 & 9000 Matrix Management / Performance Improvement / Waste Management / Supply Chain / Dashboards
As an experienced Plant Operations Manager in multiple industries, I have improved processes, reduced costs and met deadlines in manufacturing and distribution. With particularly strong skills in labor management, compliance and training, I have driven measurable improvements in productivity and logistics. I’ve managed budgets to $1M and staff to 300.
Recognized by management in all the companies I’ve worked for as an expert trainer, I created an environment in which people were encouraged to ask questions, suggest improvements and propose innovations. This philosophy also flows through my other key skills:
q Leading Matrix Management cross-functional teams, completing projects on-time and within budget
q Applying Lean Manufacturing management principles to gain productivity improvements
q Facilitating Change Leadership to encourage personal achievement, adaptation and reduced turn-over
q Achieving stretch goals, maximizing employee performance, reducing costs and improving productivity
Education and Special Training: MS, Industrial Relations, Pace University, BS, Psychology, St. Thomas Aquinas College. Six Sigma in Practice (DMAIC Phases, SIPOC Mapping), The Process Excellence Model, Lean Management Thinking, Dashboards in Practice, Train-the-Trainer.
Championed third shift operations of Johnson & Johnson [previously Pfizer] production and packaging plant for ten years. Results driven Manager with broad-based manufacturing experience providing focused leadership, proven problem solving ability, ensured effective communications and implemented exacting business strategy. Leader offering experience in senior-level operations, production, materials, quality assurance, safety/health/environment and customer services. Responsible for all third shift plant operations inclusive of FDA and OSHA compliance.
Spearheaded opening of new packaging plant for Organon, with no lapse in production. Given overall operations responsibility to open new, state of the art $3.5M packaging plant in another state. Applied Matrix Team Management to downsize closing plant while hiring and training staff of 200 for new facility. Maintained downsized workers’ production levels, morale and compliance using re-employment initiative. Achieved all agency approvals and opened plant on time.
Prevented packaging department shutdown at Organon for FDA violations and increase efficiencies by 23%. Upon promotion to Packaging Manager, took over to find serious FDA violations in production processes. Inspected each station with staff, highlighting each violation. and training on compliance. Cleared violations by training staff to adhere to compliance and accept accountability. Avoided fines and loss of revenue, while increasing productivity.
Improved production efficiency and reduced staff at Sound-Tech, achieving 37% increase in profitability. Upon becoming Plant Manager, determined organization lacked goals, objectives and accountability. To fix these problems, used Lean methodology to streamline organization, eliminate wasteful positions, create standards and conduct routine audits of performance. Led Matrix team to find efficiencies, reduce costs, minimize downtime and waste.
Turned-around Johnson & Johnson manufacturing set-up teams’ operations performance, obtaining 99.2% clearance rating. Set-up teams did not have supervisor to guide activities leading to much discourse, infighting and poor performance. Saw problem and took on supervision of all shifts. Provided training, real-time conflict resolution, routine meetings and stretch goals. Morale improved significantly. Department achieved 100% timely performance and received 41% of safety awards.
Independent Consultant, Pharmaceuticals [Manufacturing, Packaging, Quality Assurance, etcâ€¦], 2008 – Present
Owner/Manager, Resume Writer Unlimited, 2008 – Present. Professional resume writer, provide tutorial employment website tutorial and interviewing technique instruction. Mentor colleagues toward active employment.
Shift Plant Manager/Team Leader, Johnson & Johnson, 1999 – 2008. $2.7B pharmaceuticals manufacturer. Responsible for all 3rd shift plant operations and facilities, including regulatory compliance, manufacturing, packaging, QA/QC, warehouse, maintenance and security. Launched first prescription drug packaging department line.
Plant Manager/Training Manager, Sound-Tech Communications, Inc., 1994-1999. Custom communications equipment manufacturing and assembly plant. Responsible for staff and operations of production, packaging, distribution and warehouse departments. Managed staff of 75 – 100.
Plant Manager, Organon, Inc., 1988 – 1994. $4.7B prescription pharmaceuticals manufacturer. Oversaw all plant functions including HR, employee training & development, budgets (capital and annual), packaging, maintenance, QA/QC, warehousing, distribution, plant security, safety and compliance. Managed budgets to $1M and staff to 300.
Previously: Plant Shift Coordinator, Barr Laboratories. Section Supervisor, Novartis, Inc.