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Manager Continuous Improvement

Macungie, Pennsylvania, 18062, United States
January 02, 2018

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**** ********* *****, ********, ** 18062 Phone: 484-***-****



Proven Manager, with over 25 years in the plastics and filling industry. I have Extensive experience in multiple management positions within the industry including Corporate Quality, Production Management, Process Management, Engineering, and Technical Services. Have lead Safety Teams as the Safety Coordinator. Lead continuous improvement teams implementing positive corrective actions. This includes working directly in partnership with customers on needed actions implemented.

I have assisted multiple corporate sales staffs in building relationships and forming partnerships with customers, assisting with line issues such as labeling, capping and conveying.

At the plant level, I have developed and written proven SOP’s, handled all audits including pharmaceutical. Lead a team that succeeded in having a plant AIB certified.

Worked on engineering teams installing in-line blow molding and filling operations when I was with Cott Beverage this included budgeting labor, hiring all labor, implementing GMP’s and SOP’s. Organized and conducted all training activities.

Developed a system over the last 20years that while optimizes the utilization of labor improves quality and safety at the same time. This system is lean manufacturing that I call “Total Ownership”. My last 3 companies that I worked for had me implement in all of their plants across the country and in Canada and Europe.


Alpha Packaging/Yorkbridge Packaging August 2005 to October 2017

Corporate Quality manager / Technical Service Manager

Oversaw four plants quality departments. Quality managers in each plant reported to me on a dotted line. My main duties were to install my” Total Ownership” system in each plant, monitor all complaints, corrective actions and conduct and manage internal auditing. Can explain in more detail during an interview.

Oversaw the merger of Alpha’s Brooklyn facility, into the new Pennsylvania facility, formerly Yorkbridge Packaging.

Managed the Yorkbridge customer relationships and building ongoing partnerships while Alpha grows the amenity side of the business.

Alpha Packaging, has adopted a “Total Ownership” system I have developed over the last 15 years. They had me traveling to their other facilities to implement and train their employees on the system. This system optimizes labor utilization while improving quality.

Responsible for managing all customer relations from any new ongoing project, technical support or quality issues in tandem with the sales group.

I am the primary contact that Natures Bounty wants all technical issues to go through no matter what Alpha Packaging facility produced it. Natures Bounty is one of Alpha’s largest customers.

Handled all audits including pharmaceutical and food audits.

Performed internal audits of multiple plants to assure GMP compliance.

Captive Plastics, Lopatcong, NJ April 2002 to 2005

Operations Manager

Managed the overall operations of the plant with a total of 20 injection blow molding lines, 5 decorating (silk screen and thermage) lines with a combined production of 1.5M pieces per day, manufacturing cosmetic and pharmaceutical bottles.

Increased efficiencies by 15%

Opened up process windows with continuous improvement meetings and DOE.s

25% labor reduction by developing and implementing a “Total Ownership Program”

Instituted visual management

Using six sigma black belt skills successfully developed a process to recycle PVC from 0% to 20+%

Started safety committee and implemented a thorough accident investigation program.

Facilitated continuous improvement projects I have assigned to each supervisor.

Facilitated multi plant continuous improvement projects

Developed, documented, and implemented a “New Hire Training Program” that will be utilized throughout the company

Schmalbach-Lubeca, Inc, Allentown, PA 2000 to 2002

Quality Manager

Quality Manager of the new Allentown facility. Employed 190 people. Manufactured 1.8M food and beverage bottles per day and 2M preforms per day with 10 blow-molding machines and 13 injection machines. Was responsible for customer incident database, improving and implementing quality control plans. Plant contact for all customer relations and new product development. The first safety committee chairman at the facility.

Managed the quality budget for the plant.

Safety Coordinator – Lead safety team and audits

Improved and opened the process window to all CSD PET lines utilizing 6 Sigma processes.

Qualified the new amorphous finish at all hot-fill juice customers.

Reduced customer complaints the second year by 50%

Qualified new top-load measuring system using deflection study results

Headed the team to become AIB certified.

Organized and ran partnership meetings with the Coca-Cola filler plants.

Was the first vendor of Knouse Foods, to ever receive their Red Apple Award for customer service

Cott Corporation, Wilmington, NC 1997 to 2000

Operations Manager

On the initial team that introduced PET self-manufacturing to Cott Corporation. The PET project represented an investment by Cott in excess of $65,000,000 USD. The project enabled Cott to put a two liter PET product on the shelf at a cost of $0.40 USD per bottle. Before the buyout of Schmalbach-Lubeca, I managed the start-up operation of 4 of Cotts PET operations, Wilson, NC, San Antonio, TX, Tampa, Florida and Point Claire, Quebec. Managed training, did all employees hiring, wrote and implemented all quality and operating procedures. All facilities are in-line blow and fill capable with the exception of San Antonio.

All 4 facilities came up at 90% efficiency ahead of the start-up curve timeline.

All facilities are using the procedures I wrote and implemented.

Developed a procedure of getting quantitative data from scribe testing rather than using the bottle cutting method.

Scrap was held below 0.5%

Assisted Cott Corporation and Schmalbach-Lubeca, with the transition during the buyout of Cotts PET operations.

Utilizing Six Sigma Black Belt skills developed proven measuring systems and widened process windows.

Brunswick Container Corporation, East Brunswick, NJ [Union environment] 1991 to 1997

Production Manager

Hired as a production supervisor and promoted to production manager. I managed the reorganization of the labor force and training of employees after the acquisition of new equipment. Managed a workforce of 130 employees. Trained all supervisors. Wrote SOPs and developed new production forms that included SPC.

The first year brought the shift that was last in production to first.

Improved material handling by implementing a process that eliminated clamp trucks.

Cut cost per thousand from $13.50 to $8.95 through the acquisition of state of the art Sidel blow molders.

Reduced labor by 50%

Plant ran at 90% efficiency up to and including the last day of operation.

Johanna Farms, Flemington, NJ [Teamster Union]

Hired as a Blow Mold Technician

In-line blow/fill operation in the milk section

Responsible for 6 head and 4 head Uniloy blow molding machines, including processing, changeovers and PM duties.

Performed all labeling duties on bottles going to the filler on Rutherford and Label Air equipment.

The last 2 years I was promoted as the working foreman in the juice filler plant until the plant shut down.


Allied Technical Institute

Baton Rouge, Louisiana

Engineering; Pneumatics, Hydraulics and Polymer Science

Rutgers University: Management

Proficient in Word, Excel & PowerPoint

SPC and TQM Training

Husky Technical Training

Six Sigma Specialists

Black Belt in Six Sigma

Sidel Level 4: Certificate

I.C.I. Melinar Training

ICI Technical Course on PET manufacture and processing.

Bucks County Tech - Graphic Arts Degree

Pennsbury High - High School Diploma

REFERENCES: Furnished promptly upon request.

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