Expert Details

Expert in Business Leadership: Profitability Through Operational Excellence in Food Manufacturing

Expert ID: 735723 Rhode Island, USA

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Food manufacturing professional experienced with growing business profitably.

Forward-thinking, energetic, entrepreneurial and results-focused Operations Executive with 20 years of achievements in manufacturing operations leadership, business growth, project engineering and product development within food industry. Hands-on leader and strategic executive with business savvy and analytical skills for optimizing operations and consistent production output for business and market growth, leading teams for high-quality performance and timely delivery within progressive environment. Adaptive self-starter with advanced organizational skills leveraging on lean methodologies for managing multiple concurrent projects, innovative resolution to complex issues and streamlining processes for permanent improvements, efficiency and profitability. Excellent communication skills for team leadership and collaboration, forging relationships for success and personnel professional growth. Patient and flexible yet agile and resourceful, motivating coach.

CORE COMPETENCIES
• Manufacturing Operations
• Project Engineering
• P&L/Budgeting
• Business Management
• Growth Strategy
• Lean Six Sigma, Gemba
• Production Management
• ISO 9001, 14001, 22000
• Food Safety, FDA, USDA
• Supply Chain Integration
• R&D QA Product Development
• KPI’s Improvements
• Market Analysis and Strategy
• Culture Building and Coaching
• Prioritization and Innovation

TECHNICAL EXPERTISE
MS Office (Word, Outlook, PowerPoint, Excel) ● SAP ● AutoCAD ● Mainsaver ● MP2 ● Foxware SouthWare ● RoadNet ● Trendata ● Intelex ● HACCP ● ADP ● DayForce ● MAS 500

Expert may consult nationally and internationally, and is also local to the following cities: New York, NY - Boston, MA - Miami, FL - Newport, RI

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Education

Year Degree Subject Institution
Year: 1989 Degree: BS Industrial Engineering Subject: Mechanical Engineering Institution: Czech Technical University in Prague, Czech Republic

Work History

Years Employer Title Department Responsibilities
Years: 2018 to Present Employer: Undisclosed Title: VP of Operations Department: Executive Responsibilities:  Leader of 24/7 Production, Quality, Safety, SC, Environmental compliance of ready-to-eat refrigerated food manufacturing company with 90+ non-union associates and 10 direct reports
 Responsible for branded and co-manufacturing business growth for US and Canada, including strategy, ideation, planning, Team development and timely profitable execution
 Deliver food safe high quality products efficiently and consistently in desired quantities, on time
 Identify and implement permanent cost effective solutions in every department
 Streamline end-to-end Supply Chain and Demand Planning;
 Identify and execute annual COGS savings opportunities
 Create anytime-ready inspection environment from processes, infrastructure to employees training

Key Accomplishments:
 Reduced planned stoppages by 15% by change-overs optimization, supply chain coordination, SKU rationalization and interdepartmental communication
 Reduced unplanned stoppages by 10% by maintenance and production departments restructuring, focus on operator errors and renewed sense of urgency with completing tasks right the first time
 Realigned 2018 Team resources utilization and plant operational capabilities with markets and customer needs, P&L priority goals to increase yields, margins, efficiencies and profitability
 Improved all KPI’s: Lb’s/ManH from 89lb to 130lb, Customer Fill Rate from 85% at 99.7%, Freight$/Lb from .27 to .12, DART rate from 4.5 to1
 Turned Ops to profitability by improving all financial indicators %’s to gross revenue: EBITDA, Material Margins, Transportation Costs, SG&A, Lb’s Sold, Conversion Costs.
 Energized Sales and Marketing Teams by renewed commitment to operational excellence, employees accountability and QA process reinforcement on food safety and customers service
 Created 2019 Budgets
Years: 2013 to 2018 Employer: Sabra Dipping Company Title: Director of Operations Department: Global Operations Responsibilities:  Provided strategic leadership and management of two distinct RTE refrigerated foods manufacturing operations - plant-based dips and dairy yogurt-based dips
 Contributed to company-wide growth executing excellence and innovation
 Established company-wide SOP’s, KPI’s and GMP’s and structured follow-ups across all functions
 Successfully doubled production output and profitability vs YAG
 Led manufacturing personnel and executed just-in-time deliveries and processing of food-safe fresh ingredients and packaging materials

Key Accomplishments:
 Exceeded annual COGS savings by 10%
 Reduced Production loss time by 15% through team involvement, ownership and Kaizen events
 Led sustained improvements achieving 25% waste reduction, 99.2% on-time deliveries, 30% CPM customer complains reduction, launched 10 new items with R&D profitably
 Reached 750+ incident-free days by creating bottom-up plant-wide safety culture
 Established inspection-ready environment for FDA, military and customers
 Created savings of $500,000 annually while slashing CapEx budgets by 20%
Years: 2010 to 2013 Employer: Tom Cat Bakery Title: Director of Operations Department: Operations Responsibilities: Leader of 24/7 day-to-day operation of fresh and frozen artisanal bakery - sweets and breads - employing 240+ union employees, daily baking 450 varieties, delivering on owned 33 trucks to 1,500+ customers.

 Leader of 24/7 fresh and frozen breads and sweets baking operation with 250 unionized associates
 Developed all SOPs including precise reporting, proactive problem solving and GMP’s compliance
 Developed and executed process controls and follow up on accuracy of dough temperatures, mixing times, dividing, proofing, baking, cooling with optimized packaging speeds and labor needs
 Created operational and CapEx budgets and matrix, including employees evaluation system

Key Accomplishments:
 Increased efficiency, safety and quality standards by building high-performing team of managers and supervisors, bakers, packaging line operators and supporting departments personnel
 Mitigated Production loss time from over 20% to under 10%, by justifying capital projects focusing on full development and utilization of human and equipment potential
 Created waste tracking process and reduced waste to below 5% plant-wide by accurately identifying and measuring root-causes, setting deadlines of completion and motivating ownership of tasks
 Daily logistically aligned 1,000+ customers orders, production schedules and supplies with fleet’s 33 route trucks delivering 98.5% on-time, improved by 10% in one year
Years: 2003 to 2010 Employer: Nonni's Foods Company Title: Plant Manager Department: Operations Responsibilities:  Led all aspects of day-to-day 24/7 baked snack food manufacturing operation in 250,000sq/ft facility with 220 unionized associates
 Created, implemented and continuously improved all KPI’s – Lb’s/H, Fill Rate, Safety, Quality
 Streamlined all processes from employees training, production scheduling to SC/DP, shipping/receiving and customer relations
 Motivated and coached workforce on safety, ownership and efficiency
 Grew top line by developing and executing PL opportunities with marketplace, R&D and production

Key Accomplishments:
 Grew business by 60% in 4 years
 Increased production output for every production line by avg. 20% in under 2 years
 Reduced waste by 30% in 1 year (500,000Lb’s to below 350,000Lb’s annually)
 Improved on-time deliveries by 10% in 1 year (89% to 97.9%)
 Reduced safety record by 80% in 4 years (25 incident to under 5) and absenteeism by 40%
Years: 1991 to 2003 Employer: Bimbo Bakeries, USA Title: Plant Engineer Department: Entenmann's Bakery Responsibilities: New equipment design, installation and production lines equipment uptime improvements in 1MM sq/ft facility.

International Experience

Years Country / Region Summary
Years: 1985 to 1989 Country / Region: Czech Republic Summary: University work

Language Skills

Language Proficiency
English Fluent
Czech Fluent
Spanish Interm.
Russian Interm.
Polish Interm.

Fields of Expertise

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