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Engineering Maintenance

Washington, New Jersey, 07882, United States
April 10, 2018

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John R. Zarka

*** ********** ****, ******, ** ***02

Cell: 908-***-****


To obtain an Engineering/Maintenance/Operations management position where I may utilize my experiences and knowledge to influence the Operational growth and Profitability of the company by improving the utilization of their current manpower and equipment, reducing waste and improving efficiencies, not just for today but for the future.


Over twenty five years experience in Engineering/Maintenance and Operations, with responsibility for Capital equipment specification, allocation, approvals and validation, Equipment and Tooling design, testing and construction, Machinery modifications, Asset Utilization, Automation and Robotics, Plant/Warehouse Design and Layout, Facility Maintenance, Security and Property Management, Operational improvements, Improved efficiencies/, organization, Kaizen, SMED, Methods Improvements with various Consumer products companies.

From 2011 to Present, I have had various Temporary and Contract positions while searching for a progressive manufacturing company, in this specific and light job market.


All American Poly Maintenance Supervisor Poly-bag production

Volt Employment/WRGrace Maintenance Engineering Mdr, Chemical mfg.

Tribeca Oven Plant Engineer Bread mfg..

Emcor/Viox Services @ Alcoa Site Manager Facilities Maintenance

Bar & Restaurant 2009-2011


Opened a family Restaurant /Bar with a friendly atmosphere along a flowing river, serving comfort food and drinks while providing live entertainment and a casual surroundings.

John R.Zarka Page 2

Crest Foam Inc. Moonachie, N.J. 2007-2008

Director Engineering/Operations

Managed and Directed the Processing and Manufacturing operations on a 24/5 basis for a workforce of 100 employees.

Led the Kaizen event installation and upgrading of the Foaming process from a manual process to a truly integrated system with feedback to manufacturing, finance, operations and R&D. This system installed and validated saved the company in purchasing, manpower, scheduling, equipment relialibility and standarditation and documentation with history.

Managed all Capital projects improving the overall operation by 20

Completed the 8-10 Capital projects within 8 months time with a minimum of 10 % savings in spending

Reduced workforce by 7% through improved methods ( combined operations) and continuous improvements

Managed overall operational and chemical budgets through purchasing controls and product grouping.

Worked directly with labor relations and contract negotiations

Dimensional Merchandising Inc., Wharton, N.J. 2004 – 2005

Maintenance Engineering Manager

Responsible for all Facility and Engineering improvements in production, compounding and equipment design/modification.

Provide support to Marketing and Sales on new projects, design, feasibility and costing.

Improve line efficiencies, equipment design and utilization while providing lower costs.

Provided solid interaction with R&D for new products and processes.

Managed all Capital Improvements and maintained budgets and timelines for completion.

Utilize obsolete equipment for the production of new products, retrofit, retool

Responsible for the machine shop and tool room.

Manage, Inventory and Sell used equipment

AVON Products Inc. Suffern, N.Y. 2001-2004

Business Unit Leader Engineering

Lead all Industrial, Manufacturing, Safety, Security, Environmental, New Products Development, Facilities (building/ grounds) and Production Maintenance.

Responsible for the creation of all Capital Equipment purchases, justification, tracking and spending at an average of 3-5 million dollars per year.

Directly responsible for 8 engineers, 4 supervisors and over 60 mechanics, including all outside contractors.

Managed a Facility/Security/Maintenance budget in excess of 1.5 million dollars/yr

Lead all engineering in the areas of Cost Reduction, Value Analysis, Efficiency/Methods Improvements and equipment innovation/modification, yielding savings of 1-2 million dollars.

Direct the integration of New Products into the manufacturing environment.

Provide support to Global R&D and US Manufacturing operations within budgetary and corporate guidelines.

Provide a safe, secure and nurturing environment for the advancement of our associates.

Responsible for the transfer of all equipment to AVON’s facility in Cincinnati Ohio, including setup, installation, commissioning and training of maintenance employees within 9 months

Developed and Designed new molds and process for lipstick manufacture. And retrofit of new style molds and the conversion of equipment. Reduced mold costs by 80%, reduced the need for excessive cleaning and improved the overall appearance while enabling designs and graphics to be added to the production at minimal up front costs.

John R. Zarka Page 3

Victoria Vogue, Inc., Bethlehem, PA

Director Engineering / Maintenance 1998 – 2001

Equipment design for improved efficiencies and change over’s time reduction, using simple KISS automation and a redefinition of the methods of assembly.

Engineering, Construction and CE Certification of production machinery, built in-house and distributed to our subsidiaries

Process and Production improvements for Quality and Efficiency (yielding 15-20 % improvement)

Capital Improvements of 1-2 million dollars per year (facility and equipment) plant wide. Installed new computer controlled cutting press, increasing material yields by 10-15-% per batch and reducing change-over time by 30-40 minutes per batch.

Management of all Engineering, Maintenance and Facility staff, reducing response time and improving communications, by defining just who is the customer

Maintained 6 Looms and the dying and bleaching of woven materials to meet customer requirements.

Budget and Strategic Planning for future business expansion and internal growth.

Developed SOP’s for primary operations and to meet ISO 9001 requirements.

Robotics and Linear actuator implementation at minimal expense, improving sewing, assembly and cutting

Interaction with Product Development, R&D and Sales & Marketing

CHANEL, Inc., Piscataway, NJ

Engineering Manager 1992 – 1998

Managed all aspects of the department that has responsibility for the daily preparation and maintenance of production line equipment.

Accountable for the introduction of new products into manufacturing and development of the Capital Equipment Program in excess of 3-7 million dollars per year.

Managed Engineering and Maintenance yearly budget in access of $ 1,000.000

Managed the operation of various projects in machine design, equipment modifications and automation resulting

In 10-15 % productivity improvements.

Developed a team of machinists and mechanics for production and productivity improvements, while utilizing obsolete machinery and innovative ideas to solve problems and reduce downtime by 30%.

Directly involved in the development of SOP’s for all production equipment and maintenance operations to support GMP requirements and to provide a validated process or operation for training of employees.

Developed a process to track and manage equipment downtime with history to improve Relialibility and set accurate PM schedule.

Developed and Instituted FDA protocols, IQ’s, OQ’s, and PQ’s for various process and packaging machinery.

Developed a Training Program with PMMI to improve our overall staff of employees, in the areas of,Mechanical,Pneumatic, Hydraulic, Basic Electrical, PLC Basics, PLC Diagnostics and PLC Programming, this program was tied to defined pay increases for the tabulation of the workforce. The results were outstanding, all 45 employees completed the basic courses with a 94% or above and the 8 employees that met the electrical requirements progressed to PLC training where all passed the Final at 97% or above.

Improve Maintenance response time and quality of repairs while reducing callbacks. (RFT)

Collaborated with team of Machinists, Mechanics, and Production employees on CI, whereas the team designed and build KISS productivity improvements, reducing Labor costs by 1-2 employees per line with less than a $ 5,000 investment.

Kaizen Event for New Fragrance filling line, involved management and production employees in the design and construction of this $2.5 million dollar filling line that would be operated by 3-4 employees handling the setup, qualification, change-over and production of 12-15 SKU’s. A true success of automation and employees.


Computer skills – Microsoft - Excel, Word, PowerPoint, AutoCAD 12, AutoCAD LT, QuickBooks, various security and video programming, G –code for CNC machining, POS systems, Payroll system, attendance software and various MRP systems, CMMS, Oracle, JDE.

Manage, train and supervise all Engineering, /Maintenance Technicians, to respond to and solve downtime problems in the most efficient manner.

Manage all custodial staff to provide a professional level of cleanliness for all shifts, cGMP Standards

Manage clear and concise documents and their filing.

Manage and direct the accurate spare parts inventory to minimize any downtime and control cash outlay.

Coordination and direction of all outside vendors activities, track progress and hold accountable for the successful and safe completion of their work.

Ability to operate all machine shop equipment, such as, mills, lathe, surface grinders, drill presses, hydraulic presses, broaches, sanders, welding with Gas, Electric stick, Heli-Arc- Mig, Tig, Press brakes, shears, punch presses, chucker’s and bar machines, PLC’s.

Surveillance and Security equipment and programming for site security, (AAA-3), including video, voice, and electronics, including Covert surveillance.

Maintain all site Environmental reporting systems, for the NJDEP and EPA

Conduct all site Inspections for local, state and federal agencies, DEP,OSHA,EPA

Diagnostics of machinery sensors and controls

John R Zarka Page 6

Develop, creation and publish of operation, maintenance, repair, diagnostic, training and operation manuals

5 S’s, Kaizen, RCA, Process Mapping, Failure Analysis, Cost Reduction, Continuous Improvement, Automation and KISS Automation, Capital Project Management, Cycle Time Reduction, Process and Design improvements, Design for Manufacturability, Cost Reduction, Waste Reduction, Time and Motion Studies, Workflow Analysis

Engineering Design and Redesign, Plant Layout, Precision Measuring equipment use.

Knowledge and hands on experiences with the integration of Pneumatics, hydraulics, general plumbing, Carpentry, Single and Three Phase electrical systems, Reading and compression of blueprint and schematic

Labeling, Ink Jet printing, Laser Coding, Sonic welding etc.

Scheduling of emergency, regular maintenance/upgrades of machinery, preventative/predictive maintenance programs and tracking for break down history

Budget management, up to 5 million dollars.

Capital Projects, from inception thru final installation, from $ 5k to $ 3.5 million, with a timeframe of 2 yrs. or less.

Facilities and grounds management, including all utilities, such as Compressors, HVAC equipment, Dust Collectors, Fire and Security/Safety systems.

Collaboration with R&D, Product Development and Manufacturing on New Products.

Personnel Management of over 75 employees, including Manufacturing engineers, Maintenance managers, Facility managers, Sanitation engineer,EH&S engineer, Process/Product engineers and all associated personnel.

FAT – SAT testing of new equipment and production/process lines

Plastic extrusion and forming

Multi site facility/manufacturing setup and management, Including offshore in Haiti.


Spring Garden College, Philadelphia, PA

Degree in Industrial Engineering, June 1972

Continuing Education

Berwin School of Supervisory Skills

Predetermined Motion and Time Data Course

Zanger Miller Management Courses

Clemson University - Setup Reduction

AutoCAD 12 and AutoCAD LT Training

Rutgers Supervisory Management Skills – I

SMED - Single Minute Exchange of Dies

Rutgers Advanced Management Program - (RAMP)

Ethics training


Oracle, JDE

Predetermined Motion and Time

OSHA – 10

Cost Reduction and Quick Changeover


Contact this candidate