Expert Details
Flavors & Fragrances Operations Efficiency, Site Relocation / Consolidation, Quality, MES, Process Engineering
ID: 732037
North Carolina, USA
Expert has hands on technical expertise in a wide range of flavor and food manufacturing technologies including compounding, pressure reaction, chemical reaction, emulsions, spray dry, powders, citrus, extraction, percolation, distillation, fractionation, extrusion, encapsulation, fruit processing (batch and continuous), juice processing, natural fermentation, dairy flavors, milling, drying, freeze drying and packaging.
Expert's uses techniques including detailed review of material properties, storage, movement, consumption and forecast, and review of business processes, software, configuration, infrastructure, and software capabilities.
Expert's roles with respect to clients are to identify opportunities, draft proposals and justifications, develop detailed specifications, help select software and hardware as required, deploy best practices, facilitate change management, manage the project implementation and help establish a supporting virtuous cycle. All proposals begin with a baseline cost analysis and agreement on assumptions.
Expert has improved fragrance manufacturing, fragrance compounding and sample lab best practices across multiple international sites for a top multinational Fragrance and Flavors company. Expert evaluates site develops and justifies proposals and deploys practical ‘best-practice’ solutions that dramatically cut costs, reduce lead times, increase on-time performance, and improve quality, productivity, and OEE (operational effectiveness and efficiency) in Fragrance compounding, Fragrance manufacturing and Fragrance sample labs. Frequently, the productivity of the manufacturing or sample lab footprint can be significantly increased and possibly doubled, thereby avoiding investment in new buildings. In addition, lead times can be reduced to 24 hours or less! Methods can be integrated with ERP, PWS (perfumer's work station) or project management systems and/or bridged to industry preferred MES (manufacturing execution system) software, hardware and automation. Expert will evaluate and optimize your existing manufacturing and sample lab configuration to get optimal value from it.
Expert's techniques include detailed review of material storage, movement, consumption and forecast, and review of business processes, software, configuration, infrastructure, and software capabilities.
Expert's roles with respect to clients are to identify opportunities, draft proposals and justifications, develop detailed specifications, help select software and hardware as required, deploy best practices, facilitate change management, manage the project implementation and help establish a supporting virtuous cycle. All proposals begin with a baseline cost analysis and agreement on assumptions.
Expert led the highly successful post-merger Operations Integration of two North American flavor and fragrance companies wherein 4 manufacturing sites and related activities totaling over $130MM business/ sales volume were transferred and consolidated into 4 other manufacturing sites. Over 15 different flavor and fragrance technologies were transferred along with their supply chains and supporting business activities. Project was completed months ahead of schedule while retaining all customers and improving overall on-time performance across the North American division by 6 percentage points. Project was implemented into SAP ERP. Expert was subsequently sent to Europe to support similar efforts which heretofore had degraded customer on-time performance to under 20%.
Expert designed the consolidation strategy and methodology which applies to operations transfer, business volume transfer and consolidation activities. Methodology consists of explicit strategic framework, supporting custom designed software tools, project team structure and task management, all designed to ensure complete continuity of supply chain while coordinating all changes in operational activities with the team that is responsible for maintaining internal and external customer relationships.
Expert has applied his experience in process development and start-up, best practices in manufacturing and operations and business process optimization to develop the entire supply network of outsourced contract manufacturing for a start-up company valued at 25MM Euro as it went public. The network including strategic sourcing, ingredient, primary packaging, labeling and sub-assembly sourcing, quality services, quality audits, manufacturing and packaging of EPA conforming emulsions, liquid sprays, aerosols and powders, plus FDA OTC conforming aerosols, plus warehousing, and distribution.
Expert also developed a similar contract manufacturing and supply network in India (Mumbai area) to support prospective business opportunities.
Expert has provided expert witness services to legal representative (law firm) defending a client in regards to fragrance manufacturing, formulation and packaging defect liability case. Expert provided assessment of manufacturing process and review of evidence indicating root cause and liability. Expertise extends to fragrance and flavor materials, manufacturing, production, processing, packaging, products, finished goods, materials storage, materials handling, manufacturing procedures and process, process controls and measurements, manufacturing equipment selection and operation, process selection and optimization, non-conformance detection and corrective action resolution.
Education
| Year | Degree | Subject | Institution |
|---|---|---|---|
| Year: 1992 | Degree: Ph.D. (All but Defense) | Subject: Biochemical Engineering | Institution: Columbia University |
| Year: 1981 | Degree: M.S. | Subject: Chemical Engineering | Institution: University of Virginia |
| Year: 1978 | Degree: B.A. | Subject: Chemistry | Institution: Wesleyan University |
Work History
| Years | Employer | Title | Department |
|---|---|---|---|
| Years: 2014 to Present | Employer: Undisclosed | Title: Principal | Department: Principal |
Responsibilities:He is providing consulting services to Flavor, Fragrance, Cosmetic, Essential Oil, Coatings, Food manufacturing companies in the areas of Operations Efficiency, Business Relocation / Consolidation, shop floor optimization, material flow optimization, optimal use of MES (manufacturing execution software) and automation, best practices in lead time reduction, shop floor efficiency, warehouse activity control, manufacturing cost reduction, sample services and more.He is providing expert witness services in regards to manufacturing and process defects, non-conformance and CAPA issues in the flavors, fragrances and consumer goods industries. He is also expert at analyzing global supply chain and/or market analysis for Flavor & Fragrance materials including bio equivalent ingredients and products. |
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| Years | Employer | Title | Department |
| Years: 2012 to 2014 | Employer: TyraTech Inc. | Title: Senior Director, Manufacturing & Supply Chain | Department: Operations |
Responsibilities:He wrote the natural ingredient global supply chain analysis portion of the information packet to go from private to public IPO on the British AIM (similar to US Nasdaq). He launched 7 commercial and retail products. He enhanced TyraTech's contract manufacturing, sourcing and distribution network beyond B2B retail and into Big Box and eCommerce Channels. He contracted for and managed all sourcing, manufacturing, quality control, warehouse, distribution and EDI partners using RFP / RFQ and selection methods; maintained flexibility and minimum product launch costs. He completed on-boarding and EDI startup processes for retail customers, Home Depot and Wal-Mart, saving 3rd party contract expenses. |
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| Years | Employer | Title | Department |
| Years: 2006 to 2012 | Employer: TyraTech Inc. | Title: Senior Director, Supply Chain | Department: Operations |
Responsibilities:He developed strategic technology partnerships to enhance value of TyraTech technology. He established supply, planning, contract manufacturing, quality, distribution and warehouse processes. He built operational master data and business processes to support costing, sourcing, sales and operations planning, regulatory compliance and quality assurance. |
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| Years | Employer | Title | Department |
| Years: 2003 to 2006 | Employer: International Flavors and Fragrances, Inc. (IFF) | Title: Director, Global Supply Chain Strategy | Department: Operations |
Responsibilities:He defined overall supply chain strategy for global operations, helped optimize the supply network, and improve processes of supply planning, logistics and sourcing. He lead customer service and continuous improvement initiatives and sponsored best practices in process, technology, tools, management methods, and metrics. He increased productivity 20-25% and shortened customer lead time by 10 days at key sites by implementing a best-in-class "platform" in an SAP environment by combining pull, Lean/Six Sigma, MES (manufacturing execution software) and automation. |
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| Years | Employer | Title | Department |
| Years: 2001 to 2003 | Employer: International Flavors and Fragrances, Inc. (IFF) | Title: Director, Continuous Improvement | Department: Global Operations |
Responsibilities:He created and implemented continuous improvement initiatives in a matrix organization. He helped develop the strategic project portfolio of manufacturing consolidations related to a global merger and acquisition of a competitor including streamlining the supply chain and application of operational best practices. He lead the regional cross functional team in consolidating North American manufacturing sites, completing the task 6 months ahead of schedule while also improving on-time performance from 87% to 93%. This was done while consolidating into SAP. During consolidation, best practices were deployed in the areas of goods movement reduction, shop floor work center design, application of manufacturing execution software and to enhance consolidation savings, reduce manufacturing costs and improve on-time performance. |
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| Years | Employer | Title | Department |
| Years: 1998 to 2001 | Employer: International Flavors and Fragrances, Inc. (IFF) | Title: Director, Technical Services, Quality Assurance, Flavors NA | Department: Flavors, North America |
Responsibilities:He directed regional staff of 12 process engineers across six operations sites in North America. He managed the full product life cycle for a wide range of flavor technologies. He reduced non-conformance events 50%, drove culture change from reactive to proactive, designed and deployed a CAPA (corrective action/preventive action) application, realigned performance incentives and standardized metrics. He guided preparations for SAP ERP deployment at facilities in North America. |
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| Years | Employer | Title | Department |
| Years: 1997 to 1998 | Employer: International Flavors and Fragrances, Inc. (IFF) | Title: Director, Strategic Business Processes, Flavors NA | Department: Flavors, North America |
Responsibilities:He lead a global re-engineering of all Flavor Division Commercial Product Development (CPD) activities and then facilitated the system's deployment globally. CPD consolidated the global purchasing power, globalized the creative catalog and established 24 turnaround of samples, documents and quotes to all customers. He managed a regional IT staff of 12 business analysts, LAN managers, desktop support staff and consultants in providing services to 500 employees at 6 locations. |
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| Years | Employer | Title | Department |
| Years: 1992 to 1996 | Employer: Merck and Co., Inc. | Title: Research Fellow / Project Manager/ Process Engineer | Department: Chemical Engineering Research and Developmenbt |
Responsibilities:He directed teams in development, documentation, scale-up, start-up and management of multi-step chemical and biochemical processes for new pharmaceutical drug substances. The full range of reaction engineering, chemical processing and analytical methods were employed in these activities resulting in successful application of cutting edge chemical process technologies. |
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| Years | Employer | Title | Department |
| Years: 2014 to Present | Employer: Undisclosed | Title: Business Analyst, Site Optimization Engineer, Process Engineer | Department: |
Responsibilities:Provided broad range of consulting services principally involving site operational data analysis, Operational efficiency optimization, space efficiency optimization, productivity enhancement, and lead time reduction for new and existing flavor, powder blending, fragrance and cosmetic customers. Additional services include process and utility equipment design, instrumentation and optimization. Using a combination of BatchMetrics software, redesign of material flow and investment in efficiency workcenters and storage systems, customers were able to at least double capacity, reduce manufacturing costs up to 50% and reduce production lead times thereby delaying the need for new facilities by at least 10 years. |
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International Experience
| Years | Country / Region | Summary |
|---|---|---|
| Years: 1997 to 2006 | Country / Region: Multinational | Summary: He rolled out operational shop floor best practices for International Flavors and Fragrances in coordination with SAP implementation activities in Netherlands, UK, Singapore, Australia, and China. Prior to that, he lead the international roll out of global business re-engineering of IFF's CPD (Commercial Product Development / New Business Development)process and application in Netherlands, France, Italy, Sweden, UK, Sweden, and Mexico. |
| Years: 2007 to 2009 | Country / Region: India | Summary: He developed a strategic supply of a key ingredient by contracting a select supplier in Northern India. He also developed and contracted a complete manufacturing, supply and distribution network for a natural pesticide spray to be manufactured in the Mumbai region of India. |
| Years: 2016 to 2018 | Country / Region: Europe | Summary: He did flavor and fragrance assessments of flavor and fragrance manufacturing sites in UK and France including retrofit of existing site and design for greenfield site. He provide operational efficiency assessment for a sample lab in Brussels for a global consumer goods company resulting in 2x increase in productivity and 4x increase in capacity. |
Additional Experience
| Expert Witness Experience |
|---|
| Expert has provided expert witness services to legal representative (law firm) defending a client in regards to fragrance manufacturing, formulation and packaging defect liability case. Expert provided assessment of manufacturing materials, manufacturing process, manufacturing equipment, formulation process, formulation equipment, filling process, filling equipment, packaging system and packaging design, and review of evidence indicating root cause and liability. Expert combined this review with detailed evaluation of testimony under oath and other case related documents and wrote a detailed independent opinion regarding potential root causes and evidence supporting those conclusions. Expertise extends to fragrance and flavor materials, manufacturing, production, processing, transport, equipment, packaging, products, finished goods, materials storage, materials handling, manufacturing procedures and process, process controls and measurements, manufacturing equipment selection and operation, process selection and optimization, non-conformance detection and corrective action resolution. |
| Vendor Selection |
|---|
| He developed entire 3rd party supply, manufacturing, QC, storage, warehousing, EDI and distribution networks in USA for multiple commercial and retail consumer products including powders, liquids and aerosols while complying with OTC FDA, consumer product safety and EPA regulatory requirements. Similarly, in India (Mumbai). |
| Marketing Experience |
|---|
| He has been at the forefront of development and deployment of commercial support / new business development best practices in the flavors and fragrance industries that are paramount to winning new business and retaining customers, including the ability to deliver a perfect sample or sales order that complies with all regulatory, safety, religious, performance and cost parameters. He understands the inter-relationship of the processes, tools and training and the challenges of cultural change management to achieve these successes. He has helped multiple biobased ingredient companies understand the opportunities and strategies to introduce and grow their products. |
| Other Relevant Experience |
|---|
| Expert has developed unique methods, software tools, processes and project plans that ensure clean and timely execution of multi-site operations transfer and consolidation / merger projects while keeping customers happy and the supply chain in tact at all times during the project. Methodology includes movement of manufacturing capacity and technology, maintenance of all customer and vendor relationships during execution, plus clean transfer of manufacturing, QC, warehouse, software, master data, ERP and related activities during the project. These techniques were used to merge over $130MM of operational volume across 11 flavor and fragrance technologies from 4 operational sites to 4 other sites ahead of schedule while improving customer on-time performance and without disruption of the supply chain to each customer. He is a material and process technology gormand with the ability to see opportunities to apply existing technology in one area to challenges in another area. This ability was developed through a career in process (and business process) development beginning with chemical process development in fine chemicals and pharmaceuticals, continuing in flavors, fragrances, essential oils, and most recently in formulation of consumer liquid sprays, powders and aerosols. |
Fields of Expertise
flavors compounding, flavors sample lab, flavors manufacturing, fragrance manufacturing, fragrance sample lab, fragrance compounding, merger integration, contract manufacturing, outsourcing, consumer product packaging, flavor formulation, consumer product, expert witness, manufacturing research and development, supply chain optimization, manufacturing quality assurance, manufacturing efficiency, operational process improvement, manufacturing quality control, shop floor control system, manufacturing execution system, implementation, corrective action, chemical process equipment selection, chemical process equipment optimization, warehouse optimization, automated manufacturing, manufacturing resource planning, manufacturing process development, flavoring material, business re-engineering, manufacturing process optimization, manufacturing productivity, materials management, technology transfer, optimization, ABC analysis, process engineering, process optimization, food processing, business process re-engineering, manufacturing automation