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Summary
This continuous improvement expert consultant is a highly successful, experienced manufacturing/operations leader, utilizing data-driven decision making, known for guiding companies through transformational change/growth/acquisitions, developing a “strong bench of leadership talent”, promoting overall employee development and building highly effective teams that maximize stewardship and produce exceptional results. A skilled strategist, tactician and problem solver adept at improving on deliverables – Safety, Quality, On-Time Delivery as well as controlling costs and increasing revenues to enhance Profitability (EBITDA) with outstanding achievements in P&L accountability (ROI). He has been directly responsible for 14 facilities (3 startups / 4 acquisitions) with up to 350 team members that manufactured a wide variety of consumer products. A visionary leader with demonstrated expertise in creating operational efficiencies, continuous improvements (LEAN/5S) and driving quality (Six-Sigma/SPC) throughout the organization.
Highlights
- 30+ years of experience leading manufacturing
- 25+ years of total P&L improvement responsibility
- 100+ successful continuous improvement projects
- Prepared 5 companies “For Sale”
- Building Exceptional Teams / Organizational Development
- Budgeting & Forecasting
- Data Driven Decision Making
Relevant Accomplishments
- Increased pre-tax net profit by 1043% ($350k to $4M) as sales rose 149% ($18M to $45M)
- Tasked with responsibility of correcting problems of late shipments, rising costs, poor morale and upgrading the plant to handle expected dramatic increase in sales.
- Created strategic plan and operational budget. Reorganized plant layout for improved space utilization (reduced space by 50%) and revamped manufacturing processes, implementing LEAN/Six-Sigma, continuous improvement practices and streamlined supply chain. Introduced performance metrics (KPI’s), monthly Kaizen events and new supplier evaluation process to better control incoming material. Improved on-time shipping from 86% to 99.99% and fill-rate from 78% to 100%.
- Developed (In-House) Leadership Training Program and led monthly Kaizen events.
- Brought new facility online, on-time and on-budget, exceeding first year profit forecasts by over 300%.
- Integrated three new manufacturing divisions (1 startup / 2 acquisitions) into company’s operations.
- Set up new manufacturing facility, exceeding first year profit/loss forecasts by 301%. With new product coming online, identified the need for new facility to handle increased production demands. Established additional manufacturing plant; hired and trained management staff to run facility. Transferred and installed equipment for new product line. Brought new plant online, on time and exceeded all projections.
- Increased manufacturing gross margin by nearly 90% (18.9% to 35.3%)
- Streamlined operations/supply chain: Introduced LEAN/Six Sigma and continuous improvement concepts, increasing capacity over 240%, allowing the company to take on additional sales – all while reducing manufacturing space. Reduced selling expenses by 39.7%.
- Increased pre-tax net income by 317% ($1.15M to $4.8M).
- Restructured/streamlined pre-hung door frame assembly and finishing operations. Added truss assembly to the facility.
- Introduced LEAN/Six Sigma and continuous improvement concepts across operations/supply chain, increasing capacity over 200%, all without increasing space.
- Increased manufacturing gross profit by 158% ($617k to $1.59M) as sales stayed flat.
- Streamlined operations/supply chain: Introduced LEAN/Six Sigma and continuous improvement concepts, increasing capacity over 200%, allowing company to take on additional sales – all without increasing space – while reducing overall manpower.
- Increased pre-tax profits by 487% ($750k to $4.4M) as sales rose 243% ($14M to $48M).
- Improved on-time delivery to 99.5% and fill-rate to 99%.
- Increased capacity over 300%, allowing company to take on additional sales (wholesale and retail as well as domestic and international) all without increasing space or manpower.
- Streamlined operations/supply chain: Introduced LEAN/Six Sigma concepts, increasing capacity over 200%, allowed company to take on additional sales – all without increasing space – while reducing overall manpower.
- Expanded the supply chain operations to include an international distribution network.
Roles
- Principal
- VP Operations
- Corporate Operations Manager
- Operations Manager
- Information Systems Manager
Request Expert / Similar Expert
Click “request expert” for a free initial screening call with this expert or a similar expert regarding your expert consulting needs
To apply for this job email your details to haleymmagnani@gmail.com