Project Manager Manufacturing

Christopher L. Berwick

**** ****** **** **.

Crestwood, KY 40014

502-***-**** cell ********@*********.***

502-***-**** office

SUMMARY

Professional Engineer and Project Director with over 20 years experience in

four international companies, developing new converting technologies in

foil, film, coatings, laminates, extrusion and printing. Directed two

"Green-Field" sites to full operation. Completed largest complex

pharmaceutical expansion program for Alcan in North America. A member of

the Education Board of Directors' of PLGA, and well respected in the

packaging world for technology and commitment in flexible packaging

markets.

PRODUCT PORTFOLIO

Campbell Soup Labels: Redesign the ink system to improve drying

characteristics and color balance for manufacturing and customer. Change

product configuration on the off-set press to maximize number of labels per

meter.

Vistakon Eye Care for J&J: Re-engineered the manufacturing process to

enhance reverse print graphic quality. Work very closely with customer to

reduce slit to print tolerance and at the same time upgraded the lamination

process to improve barrier capability with thinner substrates.

Lamination barriers for Pharmaceuticals: Develop new product for film and

foil barriers in pharmaceuticals and some medical products. This was

accomplished by thinner substrates, new adhesive/lamination systems and

enhanced quality control systems. Specifically, established new standards

for green bonds, and aged bonds. Also did validation testing to reduce

product curing time to allow customer to receive orders faster and in

smaller quantities.

Digital Film for 3M: Develop a new X-Ray film process for 3M using a new

chemical and manufacturing process. This joint venture required both

parties to supply process and funding. The project was a great development

effort.

Blister Pack Foils: Supported the new blister pack lines (thermal form)

and help develop the product for in house manufacturing. These team

efforts lead to a pilot lab to test out new blister designs and customer

trials.

Capri Sun for Kraft: Lead the product manufacturing improvement to reduce

manufacturing costs and past some of the cost reduction over to Kraft. The

remaining cost reduction stayed with the plant. In this campaign, reduce

width of foil and increased line speed of the printing process were the

major cost reduction results.

Barrier Lighting for Kodak backing paper: Re-design the Kodak backing

paper for the camera system. The technique was to change the latex black

coating process to an extrusion process using new dry resins. This product

became the new manufacturing process for Kodak, and Alcan received the full

contract for the entire business.

Drafting Films: Develop for the customers drafting films using new coating

techniques with upgraded chemical solutions.

PROFESSIONAL BACKGROUND

HAMMER PACKAGING

2008

DIRECTOR OPERATIONS

Responsible for all production performance to include production P&L,

safety, HAACP, training, process engineering, hiring, quality and

implementing lean manufacturing principles.

. Resolved/re-directed the Union work force issues that lead to significant

productivity gains

. Address customer plastic/glass bottling label issues with effective

production process changes

. Increased production by using lean manufacturing techniques i.e. 5S,

statistical analysis

ALCAN PACKAGING (Formerly Lawson Mardon) 1996 -

2008

Engineering Director Alcan Flexible Global Pharmaceutical

Developed and supported corporate requirements of fast growth for a

pharmaceutical flexible packaging business in North America. This includes

directing international activities for new processes and product. Totally

responsible for all capital, process definition, training and design for a

$27.5 million expansion project to double the size of Alcan Pharmaceutical

North America growth

. Led the negotiation effort at the domestic/international level for all

contracts

. Established process/production teams under manufacturing direction to

understand new technology

. Worked together with purchasing organization on specification and project

external bidding processes

. A team player to sell the project up-scale and down-scale to the

organization

Operational Manager - Pharma Center

Responsible for all production performance to include production P&L,

safety, training, process engineering, project engineering, hiring,

quality, implemented lean programs i.e. black belt, 6-Sigma, Kaizen, 5s

. Led Pharma Center manufacturing to the highest profit levels in 2003

. Installed new shift operations and significantly increased manufacturing

flexibility with cross over training and product designed

. Recognized by key customers, i.e. Merck, Bristel-Myers,Pfizer etc. as an

innovator to pharmaceutical packaging requirements. Lean manufacturing

program results:

- Stopped production turnover in 2003

- Increased production by almost double

- Reduced scrap by 10% from 4 QTR 2002

- Introduced over 100 manufacturing improvements

- Improved on-time delivery to 90-95% level

- Introduced safety program to reduce injury

- Helped to create direction for Pharma Center

- Exceeded profit budget (EBIT) by a large factor

Plant Engineer/Process Manager

Designed and built a $12.8 million expansion for pharmaceutical flexible

packaging utilizing advanced technologies in printing, lamination, coating,

extrusion, drying and material handling. The expansion consisted of semi-

automated warehouse, tri-plex lamination, slitters, packaging area, office

space, IS systems, oxidizers, and all associated facility support.

. Integrated expansion into the existing production operation without

impacting customers

. Achieved compliance with GMP's, ISO, state and federal regulations -

Title V, and air permits

. Performed the validation on the equipment with the process engineers and

marketing engineers, presenting this to the Pharma customers

Technical Process Manager

Led Food manufacturing facility in cost reduction programs, installed new

processes to improve efficiencies and performed major rebuild of processes

with 1990 manufacturing technologies

. Implemented lean manufacturing to reduce cost on Capri Sun for Kraft.

P&L improved by 12.1 million dollars that year.

. Developed new technical markets/products both domestically and

internationally, specifically Kodak backing paper, digital paper and help

develop a partnership with the Kodak organization

. Worked closely with Polaroid, Kraft, Xerox and a major contributor for

Johnson & Johnson Vistakon

BATTERY ENGINEERING INC. 1995 -1996

Operation Manager, Massachusetts

Responsible for all production, production hiring/firing, engineering,

quality, material, application and environmental activities including

production P&L on monthly basis as well as customer relationships

. Put in place a plan for ISO 9001 and major efficiencies improving monthly

sales by over 40%

FURON CHR DIVISION 1993

-1995

Engineering Manager, Connecticut/Illinois

This $30 million operation was re-engineered using World-Class techniques

to increase the P&L line from a negative operation to a very positive

financial operation

. Directed engineers for PSA tape, foam and silicon process upgrades and

the maintenance organization

. Implemented cost reduction programs, visual factory, work cell and team

building techniques

. Became the technical consultant leader

JAMES RIVER CORPORATION 1988

-1993

Program/Project Manager, Paper/Film converting

As Program/Project Manager Europe, responsible for building a fast track

"Green Field" site in Manchester England including all aspects of the

building and start up of the plant, including project finances, hiring,

union negotiations, operational manager for production/manufacturing start

up, quality protocol, material purchase, process validation, and start up

of the customer service

. This High Performance Work Center would supply the Photo Resist and

Imagining products in Europe

. Managed this $42 million project involving over 1000 people, resulting in

a very advanced 70,000 square foot factory, which became the flagship for

the James River Corporation

. Project completed in 19 months with the first roll produced meeting all

quality requirements

Led the development of another Green-Field site in South Hadley

Massachusetts, a 250,000 square foot converting facility involved

relocation of an existing $40 million converting business

. Involved 150 operators/30 engineers in the design as part of the High

Performance Work Center effort

. The result was the $40 million converting business was not impacted

during the relocation period

KODAK CORPORATION

Process and Marketing Development

. Technically directed six (6) processes/products ranging from photoresist

and drafting films to skew adhesive coating solvent techniques with

solvent IR drying, with all exceeding 16% contribution to P&L

MILITARY SERVICE

Captain in the U.S. Army, Project Manager for US Defense Systems

EDUCATION

Rochester Institute of Technology, Rochester, New York

Master of Business Administration

Master of Science/College of Business, (Statistical analysis)

Norwich University, Northfield Vermont

Bachelor of Science in Mechanical Engineering, Minor Electrical Engineering

Numerous Clinical chemistry courses

Co-author of 410K regulation under FDA control under the leadership

of Ted Kennedy

Contact this candidate