Work History

Work History
Jan 2013 - Present

Director Quality Operations and  Business Process Improvement

SBG Global

SBG Global- Management and consulting firm specializing in business process development, quality systems improvements and re-branding and re-imagining small businesses.

Mitigating business failure by providing solutions through Continuous Improvement initiatives and Business Process Management. Developed core set of products and services for small and medium size companies in the support of Planning, Operations, Quality, Lean Methodologies, Business Management Systems and Competitive Intelligence. Partner and Collaborate with business owners with product development, sales, commercialization, patent defense, marketing and supply chain strategies and helped business owners re-imagine their businesses as if they had no limitations. Helped business owners secure funding, establish business credit and manage their budgets in support of their marketing and business strategy.

SBG Client: Specialty Pharmacy Co.

Specialty Pharmacy in AZ implementing Lean Business strategy to promote excellence in Safety, Quality, Cost, Performance and Environment. Performed Business Process Analysis. Created Standard Operating Procedures and developed Regulatory Compliance Strategy.

  • Performed 2 Kaizen Events resulting in 40% reduction in order processing time
  • Reduced packaging errors by 50% and subsequent waist by 300%
  • Trained employees in Lean, Six Sigma, Root Cause Analysis and other problem solving tools
  • In accordance with DEA and Federal Guidelines developed the following
    • Diversion procedures, Inventory control for Schedule I, II, III substances, Security protocols, Record keeping

 

SBG Client: Precision Machine Parts Company

Leading supplier of complex machine parts for the semiconductor, aerospace, medical device and defense industries, experienced a catastrophic lightning strike disabling 40% of manufacturing capacity.

Developed rapid changeover procedures, analyzed business processes and quality systems. Developed change control process. Hired and trained a continuous improvement manager, developed an atmosphere of operations excellence. Trained employees on Lean Manufacturing principles.

  • Rapid changeover process restores 25% of production in under 2 weeks
  • Increase overall manufacturing efficiency by 70%
  • Identified and eliminated 3 redundant processes resulting 25% increase in employee utilization
  • Developed Quality Management System and Training Compliance program

 

SBG Client: Interim CEO, Geno’s Foods

Food manufacturing company (pork, gourmet sauces, and blended ingredients) was inherited by client but company had not been viable for over 30 years. Client in urgent need of operations and supply chain strategy, marketing strategy, IP management, formula and ingredient optimization and a comprehensive business plan.

Developed relationship with 2 contract manufacturers based on supplier strategy which included ability to utilize international relationships for manufacturing in Asia. Optimized and streamlined formula based on regional preferences and availability of ingredients. Created a worldwide, multi-variable sourcing matrix based on formula utilization in the region. Developed Supplier Quality Agreements with contract manufactures to include critical to quality parameters and KPI’s.

  • Reduced overall formula cost by 20%
  • Increased ingredient sourcing efficiency by 300%
  • Negotiated contracts with 2 major distributors representing over 120 grocery stores
  • Shipped over $330,000 in product in the first 6 months

 

SBG Client: Domestic Brewery

With worldwide shortage of hops and an unsustainable contract manufacturing relationship, domestic brewery in NY was in need of supply chain and risk mitigation strategy and an alternative contract manufacturer for production and future growth.

  • Developed contractual relationships with 3 hops suppliers to allow for seasonal buying and flexibility in case of increased demand
  • Capitalizing on limited availability and limited variety of hops, researched, developed and commercialized an IPA beer within a 4 month window
  • Developed primary and secondary contract manufacturing strategy to shore up short falls in supply as well as future increased capacity
  • Negotiating agreement with a leading hops supplier in Germany to grow, cultivate and broker hops in the US


Oct 2011 - Jan 2013

Director Quality Systems-Americas Region

Kerry Foods 

Kerry Foods- 6.5 billion dollar global Food and Pharmaceuticals Company with operations in 23 countries

Kerry launched massive project to consolidate quality management systems across all global operations. High risk and outdated CAPA program in need of upgrades.

Managed 3 direct reports and 46 quality managers in 5 countries in support of Beverages, Cereals, Dairy, Functional Ingredients, Meats, Culinary, Nutrition and Sweets Divisions. Developed and managed the deployment of a Global Quality Management System including prerequisite programs, FSMA, GFSI, HACCP and Sanitation programs within Kerry Americas, Canada, Mexico, Brazil and Costa Rica. Utilized SharePoint technology for Knowledge Management as well as Out of Compliance and Corrective Action investigations. Personally trained over 70% of Quality staff in the Americas in DMAIC concept and Business Process Analysis.
• Obtained 100% GQMS compliance at 30 facilities in 9 months
• Reduced backlog of Corrective Actions by 75%
• Reduced CAPA investigation cycle time by 60%

Apr 2002 - Oct 2011

Director, Quality Systems and Business Development

Quality Systems Improvements QSI, Inc

QSI- Multi-disciplined consulting firm specializing in Operations, Supply Chain, and Quality Management Systems

QSI Client: Medical Device Company
Lead Quality Consultant:
Mid-size medical device company in Missouri experiencing overload of quality complaints since expanding to new facility and doubling capacity. Quality systems and staff inadequate to support the number of complaints. Evaluated Customer Compliant Process in accordance with ISO 13485. Developed detailed business process map utilizing senior personnel and other staff. Identified critical to quality parameters and isolated high frequency areas.

  • Reduced Customer Complaint Backlog to 0 in 6 months
  • Increased efficiency of complaint handling process by 500%
  • Eliminated 2 redundant procedures

QSI Client: Snack Food Company
Interim Quality Director
High turnover, leadership void and customer flight created a need for rapid intervention.

Managed QA and Regulatory responsibilities, developed Quality Management System and Standard Operating Procedures. Developed quality systems and procedures from the ground up. Managed 21 direct reports and 2 indirect reports. Created a culture of continuous improvement emphasizing Quality and Data driven decision making. Created a new image for the corporation based on world class quality.

  • Achieved SQF Level 2 Certification.
  • Reduced products on hold by 90% Increased Right the First Time percentage from 88% to 97%
  • Reduced Cleaning turn-around time by 2 hours between changeover
  • Reduced product release time by 6 hours per batch
  • Maintained a Zero customer complaint rate for over 6 months
  • Implemented employee cross functional training program

QSI Other Notable Project and Accomplishments

  • Developed Change Control process for large Pharmaceutical company in upstate NY
  • Reduce backlog by 90% in 6 months
  • Increased efficiency of Change Control approval process by 320%
  • Re-engineered HACCP program for large food manufacturing facility in Bloomington, IL
  • Member of global quality systems rollout team for large pharmaceutical company in NJ
Aug 2000 - Apr 2002

Manager, Continuous Improvement, Quality Excellence

Sandoz Pharmaceuticals (a Novartis Company)
Sandoz- 100 million dollar generic pharmaceutical facility.

Developed duties and responsibilities for new department from the ground up. Charged with reducing inefficiencies in critical quality systems utilizing six sigma and other continuous improvement initiatives. Hired 3 direct reports to manage critical areas, Training, Change Control, CAPA and Internal Communications.
  • Increased efficiency of Change Control process by 200%
  • Decreased CAPA cycle time from 9 months to 3 months
  • Developed Metrics that quantified training effectiveness
  • Defined and implemented cGMP and Career Training Curriculum for Quality and Plant Employees
Aug 1999 - Aug 2000

Quality Engineer, Operations

Eli Lilly Pharmaceuticals
Eli Lilly- 20 billion dollar global pharmaceutical company with operations in 17 countries.

Managed Cross-function CAPA/Root Cause investigation teams across numerous sites in Indiana representing over 6 billion in revenue. Charged with reducing the number of recurring deviations that resulted in product holds, waste, defective product and or product destruction. Worked in Solid Dosage, Sterile and Medical device facilities.
  • Solved 2 costly, recurring multi-site Investigations with an estimated saving over two years of $600,000
  • Reduced the inter-departmental investigation time by over 50%
Sep 1996 - Aug 1999

Sr. Process Engineer

Kraft Foods
Kraft Foods- Third-largest food and beverage company in North America and the fifth-largest food and beverage company in the world, with eight $1 billion+ brands

Process improvement and product development for US and Canadian market. Key member of the process cheese global optimization team formed to defend against lower cost process cheese manufactures. Won the Superior Achievement Award.
  • Reduced price of product by. 38 cents/lb.
  • Project team member for 14 million dollar capital project to implement new product launch
  • Developed HACCP Plan for new product formulation
Feb 1988 - May 1993

Nuclear Engineering Technician

US Navy Nuclear Submarine
Naval Nuclear Engineering Technician“ Nuke” United States operates one of the largest and most advance nuclear submarine programs in the world

Maintaining, operating and regulating nuclear reactor and power plant on the SSBN 655 Henry L Stimson Ballistic Missile Submarine.
  • Maintained Plant chemistry for Nuclear Operations on board Naval Nuclear Submarine
  • Researched and authored QA documentation for routine and emergency maintenance

Education

Education
1996

BS Chemical Engineering

University of IL

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