Manager Six Sigma

Joe Costa

Email: *********@********.***

Address: **** ***** *** **** *****

City: Center Valley

State: PA

Zip: 18034

Country: USA

Phone: 610-***-****

Skill Level: Senior

Salary Range: 200

Willing to Relocate

Primary Skills/Experience:

See Resume

Educational Background:

See Resume

Job History / Details:

Joseph M. Costa

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Joseph M. Costa

3395 North Bay Hill Drive aii Center Valley, PA 18034 aii H: 610-***-**** aii M: 610-***-**** aii *********@********.***

Global vice president of manufacturing/Operations

aii 24 years of progressive experience leading global manufacturing/operation teams that consistently meet key customer and regulatory requirements while continuously improving operating performance.

aii High-energy leader experienced in managing cGMP regulated manufacturing plants in the United States, the Netherlands, and Mexico.

aii Result driven leader who delivers key businessaii strategies by building strong teams, collaborating cross functionally, and utilizing systemic improvement tools: Lean, Six Sigma, Statistical Process Control, and Sales & Operations Planning.

Core Competencies

Cost Control & Cost Savings

Union Management

Continuous Improvement - Lean and Six Sigma

Cross Functional Collaboration

Multi-unit and Multi-culture Leadership

Start-ups and Change-Management

Strategy Development, Deployment, Management

cGMP Regulated Operations

Professional Experience

CERTAPRO PAINTERS OF THE GREATER LEHIGH VALLEY: 08/2011 to Present

President aii Coopersburg, PA

After completing the transition projects at Avantor Performance Materials, started a local business. As President:

ai Developed market assessment, 3 year business plan, goal, objective, and strategies.

ai Defined key roles, accountabilities, and goals in the new business and hired initial staff

ai Negotiated, purchased, and integrated a 2nd local business.

ai Achieved 94% customer satisfaction

COVIDIEN/AVANTOR PERFORMANCE MATERIAL: 1994 to 2011

Vice President of Global Operations, Mallinckrodt Baker Division aii Phillipsburg, NJ, 2007 to 2010

Led four manufacturing plants (union and non-union) and the global operation functions with 800 employees in the United States, the Netherlands, and Mexico for this $450M cGMP chemical division. In this role, I developed the organizational capability to become a stand-alone business: Restructured or created core corporate functions of Strategic Procurement, Planning & Logistics, EH&S, Quality/Regulatory, and Engineering. In addition to these corporate functions,

Key Results:

aii Reduced cost of goods sold, as a percent of net sales, by 10% over 4 years by implementing of a 5 year Operational Excellence program using Lean and Six Sigma tools to standardize key manufacturing processes and rationalize our global manufacturing processes/products.

aii Delivered $10 million in savings by implementing low-cost country sourcing, qualifying dual raw material sources, and renegotiating key vendor contracts.

aii Reduced recordable injuries 40% to 1.6 TRIR by implementing global best practices and increasing employee involvement/accountability while meeting new regulatory requirements.

aii Reduced customer complaints 35% by implementing statistical quality control programs, globally standardizing process control methodologies, and collaborating with key customers.

aii Earned the 2009 Presidentaiis Achievement Award for excellence, one of two granted in ten years. During the year I led my team through the global economic crisis with reduced injuries, improved quality, and a $1 million dollars gain to budget despite a 15% volume drop at the plants.

Professional Experience (continued)

Director of Manufacturing, Mallinckrodt Baker Divisionaii Phillipsburg, NJ, 2005 to 2007

Led the four of the manufacturing plants in Covidienaiis Pharmaceutical division with 800 employees. In this assignment, I was tasked to turn around the divisionaiis poor financial performance and service levels.

Key Results:

aii Reduced customer backorders 80% from $3 million to $0.6 million by working with Marketing and the plants to better understand customer requirements, improve equipment reliability and vendor performance.

aii Reduced costs $4.0 million annually utilizing Six Sigma and Lean Manufacturing tools as part of a global cost reduction program.

aii Supported three years of +10% annual top line growth while improving customer service by expanding production capacity and improving manufacturing efficiencies

Plant Manager, Medical Device Division - Augusta GA, 2000 to 2005

Led 800 employees to make a step change in global cost and quality competiveness. Engaged employees to meet this objective by implementing Lean Manufacturing practices and improving the siteaiis process technology.

Key Results:

aii Increased inventory turns from 19 to 32 by implementing Kanbans within the plant and, through collaboration, expanded those kanbans to our vendors. Utilized the space gained to support a multi-year plan that modernized the converting lines and supported a 30% top line growth.

aii Reduced staffing by 5% and also created positions to support the development of a plant technical training program that was recognized by the Augusta Chamber of Commerce as the areaaiis best.

aii Reduced cost $1.5 million per year through development of a multi-year Lean implementation program including: 5S, Standardized Work, Kaizen, SMED, Visual Factory, Kanbans, Pokayoke, and Six Sigma.

aii Reduced plant recordable injury rate 50% to 1.3 TRIR. One of three Plants (out of 65) recognized by corporate for excellence in safety.

Production Manager, Retail Division aii King of Prussia, PA, 1994 to 2000

Led the start-up of the Baby Diaper manufacturing operation in the Retail Division of Covidien. Helped grow the business from $0 to $150M in sales in 3 years.

Key Results:

aii Started up seven high-speed diaper machines on-time and within a $40M budget.

aii Created the work system, quality system, manufacturing process to support the new business

aii Increased machine throughput from 5,000 diapers/hr. to over 21,000 diapers/hr. and reduced waste 20%.

PROCTER & GAMBLE: 1989 to 1994

Department Manager, Paper Division aii Mehoopany, PA, 1992 to 1994

Team Manager, Soap Divisionaii Staten Island, NY, 1989 to 1992

Education

CARNEGIE MELLON UNIVERSITY aii Pittsburg, PA, 1987: BS Industrial Management and Economics

CONTINUED EDUCATION:

Lean Sensei aii Villanova University Certificate 3/11

Requisite Leadership and Organizational Design Certified Trainer 2008

Six Sigma aii Covidien Blue Belt and Champion Training 8/06

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