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Summary
This Manufacturing Operations Consultant is a dynamic and results-driven Chief Operating Officer and manufacturing operations leader with extensive experience driving growth and profitability in large-scale plastics, packaging, recycling, and sustainability industries. Recognized for entrepreneurial leadership, strategic analysis, and expertise in aligning manufacturing operations with competitive market demands. He is adept at business transformation, cost reduction initiatives, and fostering cross-functional collaboration to achieve operational excellence
Highlights
- Large-Scale Business Transformation
- P&L Management / Strategic Planning
- Revenue & Profitability Growth
- Process Optimization
- Manufacturing Engineering
- Cost Control
- Productivity Improvement
- Team Leadership
- 5S
- Vendor Management
- Plant ManagerExperience
- Capital & Operating Budgets
- Manufacturing Systems Development
- Six Sigma Black Belt
Relevant Accomplishments
- Plastic Process Experience–Responsible for overseeing 54 presses which were a combination of injection molding, blow molding and structural foam molding machines. Implemented a complete preventative maintenance program and operator training along with automation upgrades to bring reliability and repeatability to an out-of-control situation.
- Customer Pricing Quoting-Revamped current quoting and pricing system to utilize engineers to review and update all standards used for quoting and pricing. This made the scheduling system accurate and efficient.As a result of this we had accurate pricing which allowed us to produce the correct products that yielded the best margins and reduced lead times by not cutting into the schedule and producing small inefficient and costly production runs.This reduced the stress on the sales team and customer service by not disappointing customers
- Business Growth & Valuation Enhancement–Spearheaded a transformational strategy that increased company valuation fivefold. This was achieved by introducing innovative new products, modernizing manufacturing processes, and streamlining operations. As a result, productivity surged by 20%, output increased by 70%, on-time delivery rates skyrocketed from 20% to 95%, and first-pass yield was elevated from 60% to 98%
- Profitability Turnaround–Led a comprehensive financial and operational restructuring of a struggling$30M company. By eliminating unprofitable product lines, refocusing on high-margin core markets, and optimizing production processes, profitability was improved from-5% to +10%. Additionally, inventory turnover rates increased from 4 to 12-15 turns per year, generating a $3.5M annual cost savings.
- Rescuing Critical Product Launches–Revitalized a multimillion-dollar global product launch that was significantly behind schedule and over budget. Established a cutting-edge manufacturing facility and an optimized supply chain, ensuring a successful launch in Europe and the U.S. The initiative resulted in a sustained revenue stream of $40M annually.
- Operational Excellence & Productivity Gains–Conducted a full-scale operational overhaul by redefining manufacturing layouts and implementing Lean and Six Sigma methodologies. Introduced Heijunk a scheduling combined with Kan ban replenishment strategies, leading to a remarkable productivity increase from 70% to 140% and achieving an on-time delivery rate of over 99%.
- Profit Margin Optimization–Executed a strategic 80/20 Product Line Simplification (PLS) initiative. By eliminating underperforming SKUs and concentrating on high-value products, direct and operational expenses were reduced by $4Mby eliminating 115 FTE, significantly improving overall profitability.
- Workforce and Facility Recovery–Led a dramatic turnaround at a failing plastic injection molding plant that had lost 40% of its skilled workforce. Revamped hiring strategies, re-established quality standardsusing statistical process controls, and restored customer confidence, ensuring the long-termsustainability of operations.
- AutomatingManufacturing Optimization–Played a critical role in optimizing a $400M injection molding business unit. Implemented Lean manufacturing techniques, increasing first-time-through quality from 85% to 94%. Successfully reduced the back log of 150,000 past-due orders, improving on-time delivery rates from65% to an industry-leading 95% within a year.
- Patents and Innovations-Awarded multiple U.S. patents for post-consumer scrap film recyclingprocesses (2013-2021
Roles
M&A Consultant, Kulesa
Chief Manufacturing Officer
Chief Operating Officer
VP of Operations, Plant Manager
Technical Manager, Operations Manager
Process Engineer, Technical Manager
