Fractional Plant Operations Consultant | Expert in Chemical Manufacturing, Turnarounds & Lean Process Optimization

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Summary 

This Fractional Plant Operations Consultant is a highly experienced plant manager and operations leader with over 20 years of proven success in senior plant management, specializing in improving efficiency, increasing business, driving cost reductions, and overseeing projects. With a track record of consistently achieving operational excellence, excelled at turning around underperforming plants, driving continuous improvements, and leading large, multi-shift operations. Strong business acumen, hands-on leadership approach, and ability to lead teams towards high performance, demonstrated expertise in scaling plant operations, optimizing processes, and enhancing safety and environmental compliance across all aspects of production, packaging, warehousing, and supply chain. 

Throughout my career, he implemented key strategies that resulted in the successful expansion of business operations, reducing customer complaints by up to 81% and improving on-time deliveries to 99%. Their focus on building effective, high-performance teams, and mentoring associates has led to increased operational efficiency, employee engagement, and the successful execution of multimillion-dollar contracts. A relentless driver of positive change, introduced Lean manufacturing practices and continuous improvement initiatives that have resulted in increased profitability and efficiency. 

This Fractional Plant Operations Consultant is a problem solver, results-driven and metrics-focused, consistently driving operational improvements with a strong sense of accountability. Experience spans across budgeting, P&L management, customer service, production scheduling, safety and environmental compliance, and regulatory oversight. With a collaborative leadership style, fostered a culture of positivity, excellence, and accountability, ensuring that safety remains a top no-negotiable priority while achieving company goals. 

With a deep understanding of operations, business growth, and strategy, demonstrated the ability to position plants as top performers within the company, contributing to the overall success and long-term viability of the business. 

Highlights 

  • Proven Leadership in Turning Around Underperforming Operations 
  • Strong Entrepreneurial Mindset with a Focus on Business Growth 
  • Expertise in Scaling Plant Operations and Introducing New Products 
  • Significant Track Record in Sales Growth, Including Tripling Plant Revenue 
  • Business Development Success, Securing $10M in New Customer Contracts 
  • Hands-on Leadership & Focus on Continuous Improvement 
  • Lean Manufacturing and Six Sigma Expertise 
  • P&L Management, Capital & Operating Budget Oversight 
  • Team Leadership, Development, and Mentorship 
  • Safety and Environmental Compliance Expertise 
  • Customer-Centric Focus, with a Proven Record of Improving Customer Service and On-Time Deliveries 
  • Pilot plant experience for 6 years 

Relevant Accomplishments 

  • Turnaround of Failing Operations: Successfully turned around underperforming chemical plants by identifying operational inefficiencies, implementing Lean and Six Sigma principles and practices, and streamlining production processes. Delivered a 40% increase in production efficiency and reduced operating costs by 30%. Positioned plants for future growth and profitability. 
  • Business Growth & Sales Expansion: Demonstrated strong business acumen by growing plant revenue threefold in some instances through strategic initiatives. Secured a $10 million annual contract with a new customer. Led efforts to expand the customer base, focusing on building strong, long-term relationships that drove consistent business growth. 
  • New Product Scaling: Spearheaded the scaling of new chemical products, for example, achieving an additional annual production capacity of 4.5 million pounds after scaling up. This expansion supported the plant’s growth strategy and increased production capacity, meeting customer demand while maintaining high standards of quality and safety. 
  • Operational Efficiency & Continuous Improvement: Drove process optimization initiatives that resulted in a 20% increase in overall plant efficiency and a 25% reduction in waste. Led Lean and Six Sigma initiatives that improved throughput, reduced cycle times, and enhanced product consistency across production lines. 
  • Cost Reduction & Process Optimization: Led cost-reduction initiatives that resulted in significant savings while improving operational performance. Optimized workflows, identified inefficiencies, and implemented process improvements that increased production capacity and reduced manufacturing costs by 20%. 
  • Safety & Compliance: Ensured adherence to safety and environmental compliance standards, resulting in zero OSHA-recordable incidents. Developed and enforced safety protocols and regular audits, creating a safe and compliant work environment. 
  • Leadership & Team Development: Led cross-functional teams, fostering a culture of collaboration, accountability, and continuous improvement. Focused on mentoring and training team members, improving team morale, reducing turnover, and increasing overall productivity. 
  • Pilot Plant Experience: Developed a deep understanding of chemical engineering principles and honed problem-solving, leadership, and communication skills. This comprehensive skill set has positioned me as skilled in process development and scale-up, capable of driving innovation while maintaining operational excellence. 

Roles 

  • Plant Manager/Multi-Plant Manager, [Pilot Chemical Company, EMS-Chemie, Cpi Fluid Engineering, SUN CHEMICAL, UCPA ]
    Led plant operations with a focus on turning around underperforming areas and scaling operations for increased capacity. Successfully expanded the customer base, securing a $10 million annual contract. Spearheaded the scaling of a new product line to 4.5 million pounds annually, while ensuring continuous process optimization and maintaining high safety standards. Focused on driving operational excellence and cost-saving initiatives through process optimization and Lean manufacturing. Oversaw a team that consistently met production targets, reduced downtime, and improved product quality. Led the implementation of continuous improvement programs that resulted in a 30% reduction in operational costs while increasing production throughput by 40%. 
  • Operations Manager, [Durez Corporation]
    Directed day-to-day plant operations, focusing on process improvements, production scheduling, and operational efficiency. Contributed to significant cost savings and enhanced plant performance by implementing Lean manufacturing and Six Sigma methodologies. 
  • Plant Engineer, [Sika Corporation]
    Played a key role in improving plant performance through engineering solutions and process optimization. Led multiple projects to enhance plant capacity, including the introduction of new equipment and systems that increased productivity. Managed technical operations and troubleshooting, ensuring minimal downtime and improving operational reliability. Played a critical role in scaling plant operations to meet customer demand, resulting in improved production capacity and efficiency. Delivered improvements that contributed to a significant reduction in maintenance costs and increased plant reliability. 
  • Production Supervisor, [Akzo-Nobel]
    Supervised production operations, managing a team of operators and technicians to ensure efficient and safe production runs. Led the implementation of Lean manufacturing techniques, improving production processes and reducing waste. Successfully maintained product quality and adhered to safety standards. Played a key role in mentoring team members, enhancing team performance, and reducing turnover rates. 
  • Pilot Plant operator/engineering technician (Organic Technologies):  
  • Duties and Responsibilities in a Pilot Plant Setting: 
  • Testing Concepts: Conducted experiments to scale lab ideas.
  • Designing Processes: Collaborated with team to develop plans for safe, efficient pilot plants.
  • Problem Solving: Fixed equipment issues and anticipated scale-up challenges.
  • Choosing Equipment: Selected and modified equipment for large-scale simulations.
  • Team Collaboration: Worked with scientists and engineers to meet project goals.
  • Analyzing Data: Evaluated performance metrics and presented insights.
  • Transitioning to Production: Assisted in scaling successful processes to full production.
  • Ensuring Safety: Followed safety protocols and regulatory compliance.
  • Promoting Innovation: worked closely with the team to implement new methods to enhance efficiency. 

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To apply for this job email your details to haleymmagnani@gmail.com