Supply Chain Project Manager

John M. Falk, MBA, CPIM

***** ***** ****** ** • Albuquerque, NM 87114 • 505-***-****• Cell (505) 681- 3311

******@*******.***

http://www.linkedin.com/pub/john-falk/a/6aa/78a

MATERIALS MANAGEMENT

EXECUTIVE PROFILE

• Highly experienced Supply Chain Professional who has succeeded in achieving results in

Supply Chain Management at headquarters-level positions for Fortune 500 companies,

mid-sized firms and highly diversified position at small, fast-growth firms.

• Excellent demonstration of leadership skills in team roles in Planning, Purchasing, Project

Management, Compliance and Manufacturing.

• Highly skilled in use of a variety of computer systems including SAP, Oracle, Microsoft

Project and Access, Microsoft Dynamics (Great Plains) and Atlas Planning Suite.

Successful track record in rapidly adapting to new environments, identifying critical

success factors and implementing plans for success.

EXPERIENCE

Private Label Select, Taos, NM

05/09 to Present

Director of Planning, Process and Procurement-

Manage the entire Planning and Procurement Department for this highly-successful cosmetics

manufacturing firm. Clients include Estee Lauder, Walgreen’s, Kiss My Face and many high-profile,

boutique firms.

• Planned and scheduled all aspects of production schedule including materials, crewing and capacity

at an average volume of 25 to 50K pieces per day, averaging $100 to$ 200K per day in production

budget.

• Implemented server-based, time-phased inventory management system inventory management

system to accurately track and report up to $1MM in raw materials and packaging.

• Reporting to the company CEO, managed 4 Function Leads and 20 staff members in daily

production. Scope of responsibility covers all aspects of Supply Chain from planning to shipping.

• Re-designed factory according to lean-manufacturing principles to permit efficient production of small

runs to $250,000 projects for key accounts. Created Standard Operating Procedures for all aspects

of production, currently the basis for ISO 9001 implementation. Certified ISO auditor.

• Managed FDA, NMOCC, ECOCERT and external vendor compliance and audits.

• Developed and implementing performance-based costing system including Access based tracking

and reporting tool.

• Performed as key liaison work with National Accounts, managing demand, production, customer

satisfaction and capacity utilization.

• Created sourcing strategies around natural and organic ingredients with great pricing volatility.

Identified opportunities to negotiate better vendor terms or establish new relationships when

necessary.

• Identified automation and make/buy decisions. Served in key technical role in developing plan to

keep all machinery operational and train employees in proper operation. Sourced all equipment,

negotiating price and terms.

Supply Chain / SAP Consultant, Albuquerque, NM

05/07 to

05/09

Provide Supply Chain, SAP configuration, and related consulting work for a diverse base of companies.

• Client list over this period includes transportation manufacturing (SAP) and a national retail account

(Oracle and other tools).

• Functional expertise in SAP APO, MM, PP and SD modules. Effective full cycle implementation

experience in configuration role.

• Overall ERP/APS systems experience includes business process design, workflow mapping, system

selection, project management, system configuration, testing, evaluation and training.

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• Other client work includes internet-related management projects including website design and

implementation.

The Bell Group/Rio Grande, Albuquerque, NM

07/05 to 4/07

Forecast Manager-

Drove the John Galt/Atlas Planning Suite implementation/optimization process for the purpose of

optimizing the forecasting, planning and ordering of over 36,000 items with total inventory values

in excess of $18MM.

• Created inventory plan to optimize safety and cycle stock quantities for 36,000 skus based on

statistical input parameters such as MAPE, order/production cycles, order fill targets and economic

order quantities.

• Generated exception management processes to identify only items where forecasts or order

quantities require adjustment before being committed to a purchase or production plan..

• Operationally forecasted over 18,000 skus using IBF best-practices, generating orders that supported

business plan and improved order fill rates from 92% to 96% over 6 months, while maintaining current

inventory levels.

KKI Inc. /Protesia Inc., Los Angeles, CA/ Albuquerque, NM

11/00 to 07/05

Project Manager-

Led the development of a $20MM soy-protein nutraceutical project that created patent-pending

technology with a diverse group of scientific, engineering, financial, manufacturing, creative

services and marketing team members. Developed business plans/strategies and presented to

key stakeholders.

• Patent-pending design that may significantly change the way isolates are processed.

• Successful project management with leading scientific experts in the field.

• Responsible for all aspects of project from technology to funding.

• Negotiated project with potential strategic partners and the venture capital community.

PricewaterhouseCoopers LLC, New York, NY

4/99 to 10/00

Management Consultant, MCS East Region Pharmaceutical/CPG Practice -

Engagement experience:

Bristol Myers-Squibb Worldwide Beauty Care (Clairol), Stamford, CT

Developed cost reduction programs, primarily by balancing inventory levels against customer

service levels in order to reach optimal levels.

• Identified $60MM finished good reduction opportunity. Strategy supported and adopted by the

highest levels of management. Included scientific mathematical approach, full automation

capabilities and tool to optimize the total company assets. Managed team of three on this initiative.

• Created operational programs help product planners more efficiently accomplish logistics targets.

• Developed a "Demand Communication" process whereby market intelligence on account-driven

product promotions would be systematically provided to the Demand Analysts. Process was

endorsed by the VP of Supply Chain, who presented it to the Forecast Initiative Team for review and

consideration.

Johnson and Johnson, Ethicon Endo-Surgery Division, Cincinnati, OH

• Developed a Sales and Operations Planning process, bringing together Marketing, R&D, Demand

Planning, and Operations at three plant locations for the purpose of sharing critical information on

product launches/restages/discontinuations, production issues, changes in demand patterns, and

production strategies. Project Director cited this initiative as one of the greatest successes of

program

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• Created "Event Management" guidelines as a standardized protocol for handling disruptions to the

normal "Lean Manufacturing" production rhythm. Extensively interviewed employees, identified and

developed canon of best practices, created necessary training documentation, and presented to key,

high-level stakeholders.

COLGATE-PALMOLIVE COMPANY, New York, NY

1/97 to 1/99

Manager of Specialty Packaging -

Managed three planners, five co-packing facilities and $21MM budget for design, manufacture

and distribution of retail point of sale display units.

• Led the cross-functional Productivity 2000 Task Force, developed and prepared implementation plan

to save $2.2MM of annual budget through process re-engineering and automation activities.

Developed new display formats, packaging techniques and production methods.

• Managed staff of four, creating daily production schedules in SAP R/3 PP module. Scope covered

an average of 200 active skus over four production plants and an annual budget of $15.2MM.

• Improved on-time delivery of projects through use of weekly regenerated effective project

management techniques and structured project bid reviews.

• Established key performance indicators, monitored results and managed production scheduling to

achieve 45 day inventory levels and 99% customer service targets.

• Pioneered development and implementation of new toothbrush display concept that will result in

annual cost savings of $500,000. This innovative technique utilized “wasted” capacity at a

production plant to produce trays in a Colgate factory, and pack them in a modular fashion where

distribution centers could configure displays according to customer requirements. Production cycle

time cut by 70%, and costs were trimmed by 65%.

Sales Forecast Manager-

Forecasted 50% of the converted case volume business for CP (Household Surface and Fabric

Care), over 120 shipping packs including Palmolive, Ajax, Murphy's, Dynamo and Handi-Wipes.

Achieved 20% reduction in absolute error by developing and implementing cross-functional

forecasting process involving Marketing, Sales and Operations Planning.

• Worked with Information Technology, designed forecast exception management tools which were

incorporated into the SAP forecasting module.

LEVER BROTHERS COMPANY, New York, NY

8/94 to 1/97

Product Planner - Managed the logistics fulfillment and new product operational planning of 37

million case/year $640 million) heavy-duty liquid detergent business, the largest volume category

in the business. Forecasted 60 different shipping packs at seven distribution locations. Reduced

average inventory investment from 50 days on hand to 23 while maintaining 99.5% customer

service levels.

• Saved $44 million through the lowering of safety stocks due to improvements in supply chain

variability, forecast error and production cycle times. Achieved Lever's second lowest forecast

error, 42%. As a member of PERT teams, launched Dove Moisturizing Body Wash and Surf

Detergent with Bleaching Action.

• Created packaging restage plan for Caress Body Wash and Liquid "all" detergent.

• Developed inventory, forecast and production plans for major detergent restage.

Recommendations were used as the basis for $10 million capacity expansion project.

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EDUCATION

UNIVERSITY OF NEW MEXICO

Post-Master’s Certificate in Finance

MBA – Operations and Management Science

Emphasis in time series, regression forecasting models, manufacturing resource planning, JIT and

continuous improvement processes.

UNIVERSITY OF ARIZONA

BS - Marketing

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