Engineer Manager

John Polcino

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

*** ********** ****** **** 215-***-****

Warrington, PA 18976 www.linkedin.com/in/johnpolcino

HIGHLIGHTS OF QUALIFICATIONS

Seasoned Manufacturing Operations professional and Mechanical Engineer with

diverse management experience. Successful at driving metrics and leading

significant change in plant culture while enhancing productivity,

performance, and business results.

. Continuous improvement of manufacturing operations with full P&L

responsibilities. Strengths include Organization, Problem Solving,

Communication and Team Dynamics.

. Plant Management in both unionized and non-unionized facilities,

Operations Management, Strategic Planning, Budgeting, Engineering

Design, Negotiating, Logistics, Field Engineering and Supervision,

Direct Customer Interface, Project Engineering and Project Management,

Technical Services and Spare Parts.

. Team-oriented management style with emphasis on Continuous

Improvement, Goal Attainment, Performance Metrics, Health and Safety,

Quality, Communication and Employee Development.

. Trained and experienced with Team Building, SOP's, Lean Manufacturing,

Kanban, Kaizen and 5S.

. Extensive knowledge of facilities and functions; Mechanical and

Structural Design, Preventive Maintenance, HVAC Systems, Utilities,

Fire Protection, National Electrical Code, Flammable Liquids and

Hazardous Material Handling, Environmental Compliance, Permitting and

Regulations, and Safety Training.

. Directly involved with labor contract negotiation and company/union

relations.

. Planned, submitted and tracked all Capital Expenditure Projects with

cost justification and ROI analysis. Maintained a consistent history

of completing the projects on time and within budget.

. Prepared and submitted annual operating budgets and long range plans.

. Member of facility implementation team for SAP business management

system.

. International business experience.

PROFESSIONAL EXPERIENCE

ITW - SIGNODE, Frackville, PA

2006 - Present

(FORTUNE 200 COMPANY)

Plant Manager

Directed all manufacturing and support operations for a $16 MM/year plastic

recycling facility. Managed eight direct reports in a 73 employee

operation that extruded PET resin pellets from recycled plastic.

Responsibilities included process improvement, safety, quality, and

employee development programs with direct accountability for P&L. Reported

to General Manager.

. Initiated and led significant positive changes to plant culture,

performance and productivity, and large scale improvements to the

facility and equipment which increased profitability by nearly 75% in

two years.

. Established written procedures for manufacturing activities which

reduced errors and improved quality and consistency of product. This

reduced re-work by over 50% and increased capacity by 8%.

. Implemented a training and development program for Group Leaders and a

succession plan for Managers that provided key back-ups for positions

and increased the flexibility of the workforce.

. Improved safety performance by 80% through training, communication and

employee involvement.

. Streamlined processes and re-engineered workforce to reduce cost of

manufacturing by 40% and restore profitability to 175% of planned

levels.

. Saved $40K annually by researching and enrolling the facility in an

interruptible power program for electricity.

. Reduced WIP and raw material inventories to less than one month

through the streamlining of purchasing, transportation and material

storage activities. Eliminated outside warehousing, saving $50K

annually.

. Organized and facilitated cross-functional teams that addressed

various safety and production issues.

ILAPAK, INC, Newtown, PA 1999 - 2006

(A Switzerland based manufacturer of flexible packaging equipment)

OPERATIONS MANAGER

Directed all project engineering, technical services and spare parts

activities for an $18 MM/year operation. Managed 5 direct reports and 12

indirect reports in three different departments. Reported to company

President.

Page Two John Polcino

PROFESSIONAL EXPERIENCE - continued

. Directly responsible for the P&L of the Technical Services and Spare

Parts Departments.

. Led safety training and accident prevention at the company facility as

well as for field service technicians traveling to customer

facilities. Total of one recordable incident in seven years with zero

lost time.

. Developed a technical training program for service engineers, project

managers, sales, and office support personnel consisting of multiple

modules that were applied as appropriate for the student. This

improved their product knowledge and customer service skills.

. Initiated a pay for skill program for the technical services

department to properly balance wages with performance while providing

incentives for employees to improve their skills and remain with the

company.

. Interfaced extensively with European manufacturing facilities and

various colleagues involved in the engineering and manufacturing

operations in Switzerland and Italy. Directly involved in equipment

design improvements, standardization, quality, logistics,

documentation and equipment testing and qualification.

AMERICAN PACKAGING CORPORATION, Philadelphia, PA 1986 - 1999

Plant Manager, Coated & Laminated Products Division (1993 - 1999)

. Managed a plant that produced coated and laminated roll stock with

annual sales of $12 MM. The plant

employed approximately 80 unionized hourly workers with 6 department

managers and supervisors.

. Negotiated union contracts, resolved grievances, and interfaced with

local and international union representatives. Improved relations led

to significant reduction in grievances and smoother negotiations.

. Led the effort that decreased accident incidence rate from 33 in 1993

to less than 2, reducing the worker's compensation insurance reserve

from $1MM to $150K.

. Collaborated with Philadelphia University to develop a formal training

program for Continuous Quality Improvement for all employees.

Facilitated the adoption of this philosophy and served on the Steering

Committee and various Project Committees.

Plant Engineer, Coated & Laminated Products Division (1992 - 1993)

. Developed a formal preventive maintenance program for a 4-station, 60

inch wide coater/laminator, slitters, winders, flexographic presses,

and other support equipment which reduced unscheduled downtime by 22%.

. Introduced and implemented a computerized maintenance work order

system for repairs, planned maintenance, and spare parts inventory

which helped organize the maintenance functions and improve response

time.

. Planned and managed the installation of several process upgrades

including moisture sensors, beta gauges, drying oven upgrades and a

blending and delivery system for coatings.

Plant Engineer, Consumer & Industrial Bag Division, Philadelphia, PA &

Story City, IA (1986 - 1992)

(New Facility Start-Up)

. Responsible for mechanical design, machine modifications and

facilities engineering.

. Instituted programs for maintenance work orders and trend analysis for

predictive maintenance.

. Directly responsible for all reporting requirements and compliance

with local, state, and federal regulatory agencies. This included

OSHA, USDA, EPA, air emissions, and hazardous waste management.

. Relocated to Iowa as Plant Engineer for a new green field

manufacturing facility.

EDUCATION AND TRAINING

BS, Mechanical Engineering Technology, Spring Garden College, Chestnut

Hill, PA

AS, Mechanical Engineering Technology, Pennsylvania State University,

Abington, PA

PROFESSIONAL DEVELOPMENT

Continuous Quality Improvement, SAP, Industrial Safety and Accident

Prevention, Root Cause Analysis,

DuPont STOP for Safety, Good Manufacturing Practices, HACCP, Plant

Sanitation, 5S, Procedural Auditing,

Statistical Process Control, Lean Manufacturing, Product Line

Simplification and Process In-Lining.

Contact this candidate