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Plant Manager Resume Crystal lake, IL
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Title Plant Manager
Target Location US-IL-Crystal Lake
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                                                    Candidate's Name
                                                   Street Address  HARVEST CIRCLE
                                                    CRYSTAL LAKE, IL
                                                   PHONE PHONE NUMBER AVAILABLE
                                                  EMAIL AVAILABLE

PROFESSIONAL SUMMARY

General Manager, Director Operations and Plant Manager with BS Biology/Chemistry and extensive experience in the
pharmaceuticals, foods, packaging, consumer goods and chemical processing industries. Responsibilities have encompassed
developing plants from a build-out and start-up phase through full scale steady state manufacturing, process improvements,
P&L, debottlenecking, throughput increase, inventory shrinkage, employee supervision and development. Maintenance,
Quality, Engineering, Manufacturing, Packaging, EH&S, Inventory, shipping, receiving. Multi-plant experience with thorough
knowledge of batch and/continuous processes (liquid, powder, tablets, capsules, adhesives, spray drying), plus skills in Lean,
Kaizen, Value Stream, DMAIC, OEE, IQ/OP/PQ, JIT, Supply Chain and ERP/MRP systems.

PROFESSIONAL EXPERIENCE

MY FIT FOODS, Houston TX 2012 to Current (Interim role while caring for terminally ill parent.)
Manufacturer/Packager of fresh, healthy microwavable meals.
Business Consultant
      Exploding business went from 2 locations to over 70 in 5 years, needing guidance for change management..
      Implemented warehouse procedures, including visual factory to stress accountability.
      Executed live apparel website ordering and fulfillment.
      Building same for the supplement business.
      Complete organization and implementation of WMS, and accountability for inventory management.
      Engineering automation for labeling and air removal, (gas injection) for self-life of packaged food.


MULTI PACK SOLUTIONS, Mt. Prospect IL 2009 to 2012 (Decided to help father in Houston)
Contract manufacturer and packager of consumer goods, agricultural and industrial products.
General Manager
      Joined to help grow the organization, based on increased customer interest in PVOH laundry, dish and
        chemical products.
      Complete design, build-out and move of plant, personnel and systems for engineering, accounting,
        manufacturing , packaging, warehousing, shipping, quality and supply chain.
      Complete P & L responsibility.
      Restructured operation to build accountability, based on deliverables.
      Consolidated multiple sites into one as a cost savings.
      Doubled revenue first year pushed focus onto customers that we should be a turnkey versus toll manufacturer,
        via better supply chain control.
      Drove sales, customer service, supply chain manufacturing together to ensure customer satisfaction.
      Directed trained staff, in lean, and OEE, such that sales, manufacturing etc could communicate true abilities to
       customer.
      Built operational metrics to measure KPIs, allowing staff to focus on accountability.
      Led successful launch of multiple product lines, systems for rotary liquid filling in PVOH packaging..
      Exceeded budget for gross margin, OI, and debt reduction as a percentage of sales.
      Implemented 24/7 operations to ensure customer satisfaction, leveraging CAP EX to bottom line.


CORAM HEALTHCARE & NEIGHBORCARE, Chicago IL / Baltimore MD 2004 to 2009
Two successive positions with the same CEO for the purpose of building, and running new or expanded operations, re-
organizing two separate mixing, filling and packaging operations for companies that made solid and liquid pharmaceuticals.
This CEO exemplified honesty, ethics and integrity with a total quality focus.
Director of Facilities Management and Construction   Coram 2007 to 2009 (Company acquired for $880 M.)
        Hired by Coram CEO, after consulting for them, to ensure new facilities met or exceeded corporate standards.
        Managed projects at 80 sites across US.
        Achieved BOP approval on all sites in the US, and to ensure cGMP standards were implemented and executed.
        Using location and expiration of current leases as the driver, new properties found, designed and built for the
           compounding of IV drugs
        New Clean Room specifications per USP 797 were built or retro-fit at Coram s 80 locations. Sites at 5000 to
           60,000 square feet
        Built new AIS (Ambulatory Infusion Suites) to other sites following corporate initiatives, for increased
           revenue.
        Worked with BOP, architects, general contractors, building owners, state governments, and various subs to
           ensure all projects hit schedules in time, quality, and cost.
Director of Operations   NeighborCare 2004 to 2007 (Company acquired for $1.8B.)
      Complete design and build-out of plant and equipment for manufacturing and thermo-forming high-speed blister
         packaging, of over 600 sku s in three modalities in a cGMP operation. (Total over 1800skus)
      Achieved start-up in nine months, including full facility validation FAT, SAT, IQ, OQ, PQ and start-up of four
         fully-integrated high-speed lines built to produce 1800 SKUs, based on demand forecasting.
      Built a throughput capability of 1.3 trillion doses per year, covered operations at 80 sites across US.
      Managed all CMO s ensuring delivery, quality, and cost met my expedited schedule
      Set up and attained metrics on all performance objectives
      Human resource management including hiring and training of all new staff, both management and hourly, to run
         this facility
      Put together a complete quality systems approach and all needed documentation, for a cGMP facility
      Directed inventory control, warehousing/distribution, supply chain, engineering, EH & S, security, validation,
         change control, scheduling, shipping, MRP, maintenance, QA/QC
      Implementation of MRP, CMMS, systems for a company that had no prior manufacturing, maintenance or
         inventory systems
      Lean Manufacturing implementation from conception through steady state operations, 5S, SMED, Polka Yolk,
         Value Stream, Constraint theory, Ohno depravation
      Full budget design including full Capital Expenditure for build-out, equipment, and COGs
      Site selection based on State incentives and logistics for new facility
      Management of multiple projects in excess of 20 million dollars to meet CEO s goal for start-up, ensuring
         promises to Wall Street were kept.

CHEMINS, Colorado Springs CO 2003 to 2004 (My standards for quality were not shared by ownership)
Nutritional supplement/vitamin/foods & OTC manufacturer in solid, liquid, powder, gels and solid dosage forms, 500 site-
employees.
VP/Director of Operations
        Responsible for manufacturing, engineering, purchasing, warehousing functions
        Acted for CEO in regard to FDA and DEA inspections and correspondence
        Responsible for pharmaceutical manufacturing and packaging for this 350,000 square foot facility of over
          3,600 SKU s
        Managed all CMO s achieving delivery, quality, and cost per my schedule (JIT)
        Lean Manufacturing implementation
        Negotiated contracts with customers as turnkey provider
        Directed objectives and goal setting for all departments, proving Lean manufacturing is the total lower cost
           solution.
        AIB superior rating.
        Oversaw all human resource functions and implemented new system for review process based on achievement,
           such that top performers would receive fair compensation
        Put together all validation protocols for operational areas, ensuring compliance to FDA
        Led scheduling for15 high-speed tablet presses, 10 encapsulation machines, fluid beds, mixers and 16 high-
           speed packaging lines for tablets, capsules, powders and liquids, including raw material procurement and
           meeting my finished goods schedule
        Responsible for two off site facilities for liquid fill (rotary and in-line) and animal feeds
        Oversaw inventory control, warehouse/distribution, entire supply chain, engineering, documentation,
           production, MRP, packaging, EH & S, procurement, planning, maintenance, housekeeping, QA/QC
        Managed multiple projects, ensuring deadlines were hit

DEGUSSA, Brighton CO 2000 to 2003 (Resigned for Better Opportunity)
Adhesives & sealant manufacturing for packaging
Manufacturing Manager
       Won the President's Award for Outstanding Achievement in 2001 in this company of 48,000 employees in an
          industry which I had no prior experience, proving LEAN thinking is key and not industry specific.
       Rotary fill operation.
       Implemented Lean Manufacturing
       5/6 S, SMED, Polka Yolk, Value Stream Mapping. Kaizen events
       Increased productivity ratio from 200 lb./man-hour to 280lb./man-hour in manufacturing and high-speed
          packaging
       Built a company-wide system for air pocket removal in material processing streams achieving a net throughput
          increase of 30%
       Pioneered and implemented removal of vacuum transfer of products by altering mixer configuration, allowing
          for increased revenue through decreased manufacturing costs, a savings of 12%

HAUSER CHEMICAL RESEARCH, Boulder CO 1990 to 2000 (Plant Acquired and Closed)
Batch & Continuous processes - Manufacturer of APIs, Injectable drugs, Functional Foods, Nutraceuticals, and Flavors
Plant Manager 1991 to 2000
        In this organization progressed from manufacturing operator to plant manager in under one year, starting as a
            base OP I, will discuss in detail during interview
        Took over a Hauser facility due to customer complaints and immediately negotiated a performance plan with
            the customer providing hard delivery dates that were hit on schedule, all targets were met within one month
            of my appointment to PM
        Rejuvenated this poorly performing operation by increasing throughput over 440% for bulk APIs, in 30 days,
            using 5 S, Value Stream Mapping, Kaizen, and knowing where to put the X.
        Achieved county approval to continue business after multiple waste water infractions prior to my arrival,
            pulled clean sanitary sewer ratings and always succeeded after with Boulder County.
        Managed all facets of sub-contract manufacturing including transition to a complete commercial product
            drying program using CMO s for (off site spray drying), at multiple locations, supplying three Hauser
            facilities with directly compressible powders
        Through sustained vigilance ensured all subcontractors performed beyond expectation and within cGMP
            compliance
        Oversaw all activities including operations, engineering, validation, change control, human resources, FDA,
            AIB, OSHA, DEA, Kosher training, scheduling, maintenance, supply chain, capital expenditures,
            warehouse/distribution, procurement, budgeting, EH&S in this highly regulated industry.
        AIB Superior rating.
       Utilizing new process engineering designs, (multiple product lines, my designs), achieved increased throughput
           40% while lowering labor costs, via Lean Manufacturing, gross value 4 million dollars.
       Experienced in Liquid filling both rotary and in-line.
       Trained staff in company-wide customer connected training initiative allowing for greater customer service,
           internal and external
       Mentored/coached several self-directed work teams
Operator / Production Supervisor 1990-1991(Promotion.)
       Promoted from an Operator to a Supervisor level within six months and was transferred to oversee a plant
           within one year.

EDUCATION
BELFORD UNIVERSITY, Dallas, TX
  B.S. Biology/Chemistry, 1990

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