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Plant Manager

Pittsburgh, Pennsylvania, United States
January 23, 2018

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Alexandra M. Kavoulakis

Senior level cross-functional manager known for improving both business and technical processes; Strong advocate for process improvements in complex and changing workplace environments. Leadership and hands-on experience across all operations and supply chain areas, especially manufacturing and software. Hallmarks include leadership, team orientation, strong analytical abilities, critical thinking, and relationship building across functional areas.

Core Competencies

Manufacturing, Supply Chain, Operations, Quality Management, ERP, Plant Maintenance, Process Engineering, Procurement, EAM, Cost Accounting, Product Development, R&D, Lean, 6-Sigma


SCA Technologies Pittsburgh, PA

Software company providing unique category sourcing and cost management solutions to maximize profits by managing market, supply, and demand volatility.

Program Manager 2014 – 2017

Responsible for delivery of all software implementations, supply chain, and support projects in a $5-10MM portfolio for major quick service restaurant customers.

Key accomplishments include:

Reduced customer support calls by 40% and blocker incidences by 35% YOY through improved and documented release testing process.

Developed standard implementation footprint for second major customer, reducing time from 6 to 2 months.

Reduced cost of data services through documentation of Standard Operating Procedures and process improvements. Reduced support personnel while adding major new customer.

Improved product management specifications through organized collection of customer requirements.

Managed team of 20 professionals split between Pittsburgh and India. Worked cross-functionally with product management, software development, and QA teams to define and deliver new software functionalities.

Worked in coordination with account managers as liaisons to key customer management and users.

Sensible Organics Beaver Falls, PA

Growing manufacturer of USDA-certified organic personal care products, including lotions, hand and body washes, and body butters. Also an extensive line of private label contract manufacturing of other personal care products.

Plant Manager February –November 2013

Responsible for all aspects of the manufacturing process in non-union facility including production operations, capital projects, maintenance, logistics and customer service, inventory management, and safety.

Key accomplishments include:

Designed and managed project to open new 7500 sq. ft. manufacturing facility for filling products.

Developed process to bring lotion and wash manufacturing into control with tighter product specifications.

Initiated employee safety programs and revived plant safety committee.

Developed inventory tracking procedures for ingredients to improve control and traceability.

Project manager for capital projects including water heating and chilling systems, new facility, and high viscosity pumping equipment.

GenesisSolutions, Inc. Ridgefield, CT

Enterprise Asset Management company providing process improvements, technology implementation, and engineering services to establish and maintain world-class maintenance and asset management.

Principal Consultant at Pfizer Inc. 2011 to 2013

Provide business and technical expertise to implement asset maintenance systems at client sites and improve performance of the key maintenance functions. Manage implementation projects, define and analyze business processes, develop implementation plans and user training, and prepare required documentation.

Key accomplishments include:

Managed implementation of Infor EAM 8.4 at Pfizer’s Andover, MA biopharmaceutical facility and Pfizer’s Madison. WI pharmaceutical plant to meet all requirements of the biopharmaceutical industry. The implementation included transferring the preventive maintenance and calibration programs from other software, defining new processes in compliance with FDA requirements, and training all users.

Developed an MRO parts storeroom strategy for the Pfizer’s Richmond, VA manufacturing facility. Assessed current processes and inventory and developed a transition plan to implement.

Pinnacle Foods Group, LLC. Cherry Hill, NJ

Growing manufacturer of prepared food products with facilities throughout the US.

Director, Business Practices - Manufacturing 2005 to 2011

Facilitated the relationship between the Information Technology department, manufacturing facilities, and business units to design more effective business processes. Drove the standardization and simplification of processes in the BPCS ERP system at existing facilities as well as integrating new acquisitions. Developed new capabilities for Corporate Procurement, TPM, and Quality Assurance groups. Implemented OEE (productivity) measurement processes across all union and non-union manufacturing facilities. Key accomplishments:

Definition of the standard manufacturing footprint for the BPCS 6.0.04 ERP system including lot traceability from purchase to finished goods, materials requirements planning, purchasing, shop floor reporting, and inventory control. This footprint allows full ERP implementation at large facilities in 3 months or less.

Configured and implemented Infor's EAM (DataStream) for maintenance management at all facilities. Enhanced the scheduling function, simplified work order assignments, and designed the financial interface to automatically assign cost centers and remove user errors. Redefined KPI’s for more accurate performance tracking. Designed new corporate-wide process for non-maintenance miscellaneous purchases.

Designed new tools and capabilities for corporate purchasing. Supported the start of ECSourcing’s FlexRFP software RFP’s on ingredients with auctions. Designed and implemented a contract management system that centralized all purchasing legal documents into one database. Developed a spend analysis from AP and purchase order data that allowed drill-down analysis on 16 key parameters.

Designed and implemented a company-wide web-based supplier corrective action request (SCAR) system with Corporate QA. This enables all plants to track and manage supplier problems in one interactive web-based CAPA system and allows evaluation of supplier capabilities and performance.

Implementation of CDC Factory OEE productivity measurement system including development of standardized definitions and methodology across 7 facilities. Also implemented the interactive quality module to capture and analyze product data throughout the production run, reducing downtime, improving product consistency, and saving money from overfill of product.

Redesign of a frozen food plant footprint to improve space utilization, eliminate outside storage facilities, improve people and material flow, and meet SQF and GMP requirements for food safety.

Interface Solutions, Inc. Lancaster, PA and Fulton, NY

Mid-size manufacturer of materials for gaskets, floor backings and other specialty businesses. ISO9001 certified.

Business Systems Architects Leader 2000 to 2005

Spearheaded the thought leadership resulting in simplified and standardized business processes across 4 manufacturing facilities and across corporate accounting and research operations. Identified the issues to be resolved, presented findings to Management and recommended final solution. Led the application development (BPCS 6.0.04 ERP system), communication to functional area owners and implementation with all system users at every level of the organization. Breadth of experience includes successful implementation of shop floor user interface, manufacturing reporting, maintenance management (ELKE) with capital project cost tracking.

Key accomplishments include:

Implemented a fully integrated enterprise system, reduction in monthly closing times from 4 days to 2 days, restructuring and consolidation of responsibilities to improve efficiency among facilities.

Received company-wide recognition for depth, breadth and expertise of work including two “General Manager Team Awards” as well as one “Manager’s Award”.

Armstrong Industrial Specialties Fulton, NY

A fully owned subsidiary of Armstrong World Industries manufacturing floor backings and gasket materials.

Team Leader for Quality and Manufacturing: 1998 to 2000

Solely responsible for the design and specification of the Quality Management System and the Production Activity Reporting during a new BPCS ERP system implementation. Developed the strategic plan to address business process issues and opportunities. Developed reports for key performance measures and tracking. Designed data capture and reporting for all QC data. Key accomplishments include:

Successful Implementation on the first attempt in the two main manufacturing facilities.

Leadership, analytical abilities and expertise resulted in promotion to “Business System Architects Leader.”

Manager of Converting Operations 1995 to 1998

Cross-functional production and technical manager in a very complex union environment. Owned P&L for a production unit of 35 union employees and 5 staff members across 3 shifts, 6 production lines, and the warehousing/shipping operations for the plant. Key responsibilities include managing all technical projects, improving product quality, planning department staffing, union contract management within the department, logistics, and ISO 9001 documentation. Extensive involvement in resolving product complaints and working with marketing representatives to assess capabilities for customized products. Key accomplishments include:

Process improvements in anti-stick coating capabilities to control application thickness and improve visuals.

Installation and startup of a new lamination line to eliminate customer delamination failures.

Department-wide scrap reduced by 20% YOY as a result of my technical process improvements.

Productivity increased 10% per year on average and customer complaints reduced by 75%.

Armstrong World Industries, Inc. Lancaster, PA

The leading U.S. manufacturer of vinyl flooring and building products for consumers and commercial buildings. Also manufactures industrial insulation, gasket sheets, and adhesives. Fortune 200 company

Chemical Engineer to Sr. Research Scientist Until 1995

Held a progression of technical positions in basic Research & Development to Product Development. Developed expertise in coatings, lamination, composite materials, and paper-making. Key accomplishments include:

Designed new lamination operation that stabilized the product line and allowed new products to be released. Startup losses on the line were reduced by 50%.

Increased capacity of cure line 25% by defining standard line speeds and temperatures.

Awarded United States Patent 5,437,767 for gasket material formulation and United States Patent 5,536,565 for gasket material processing.


Carnegie Mellon University

B.S. in Chemical Engineering and Administration and Management Science

Graduated with University Honors for Service, Tau Beta Pi Engineering Society

Lehigh University

Work towards M.S. in Analytical Chemistry

Professional Affiliations

American Institute of Chemical Engineers

American Chemical Society

Tau Beta Pi Engineering Honor Society

Society of Analytical Chemists of Pittsburgh

Spectroscopy Society of Pittsburgh

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