Manager Continuous Improvement
Resume:
ALVARO A. BRACAMONTE
www.linkedin.com/in/aabracamonte
************@*****.***
Supply Network Operations Professional
Proven to Improve Business, Operation, and Technical Performance An exceptional Leader, General Manager, Director, and motivator who focuses organizations on strategic priorities to attain P&L objectives. Practices superior leadership methods forged in manufacturing startup and turnaround environments, in domestic and international businesses, employing Total Quality Management (TQM), Total Productive Maintenance (JIPM TPM), and Reliability Technology (P&G RT) techniques. Develops collaborative leadership teams focused on improving key performance indicators. Leads business and function integration programs and cost reduction initiatives. Transforms plant culture and environment to high performance organization. Specialist in creating a performance culture through process execution and talent development. Expert at applying known solutions to problems and inventing solutions to unique problems. Strong commitment to individual, team, and business development. Hands-on take charge style focuses on business growth and profitability. Intuitively analytical Leader known for personal credibility, integrity and excellent communication. Advanced skill in MS Office Suite applications. Speak Spanish. Expertise:
• Total Quality Management (TQM) Certified • Global Program / Project Management
• TPM (JIPM) Practitioner / CI Specialist • Supply Network Operation / Optimization
• Reliability Technology Practitioner (P&G) • High Speed, Continuous, & Batch Processes
• Plant Management / Engineering Integration • GMP / FDA / DEA Regulated Businesses
• Strategic Planning / Business Integration • R&D / Engineering Change Process Positions Served With Distinction:
Director of Manufacturing, Program General Manager, Supply Network Operations Manager, Plant Leader, TPM Internal Consultant, Corporate Continuous Improvement Manager, Corporate Reliability Technology Manager, Plant CI Manager, Labor Arbitration HR Manager, Production Manager, Operations Manager, Technical Services Manager, Project Engineer PROFESSIONAL EXPERIENCE
NELLSON NUTRACEUTICAL LLC (Acquired by private equity group) 2017 to present Director of Manufacturing, Irwindale and Ontario, CA Leading collaboration with Sales and R&D to ensure the introduction of new products is seamless and profitable. Leader of the continuous improvement process for the production facilities working closely with leadership to improve all processes. Accountable to meeting budget and customer expectations. Includes:
• Manufacturing Excellence – Determine annual budgetary line speeds, labor costs, loss elimination targets including capital investment, development of employees, and standard operating procedures.
• Continuous Improvement and Strategic Planning – Identify loss elimination opportunities. Charter and lead loss reduction initiatives. Advise Engineering on new technology. Benchmark and network with Nellson sites.
• Management – Lead and develop staff of Packaging Coordinator, Process Engineer, and Supply Chain analyst to include Performance Management, Learning Plan Development, and employee development.
• New Product Introductions – Determine feasibility of new products. Ensure smooth transition. CONAGRA FOODS INC 2015 to 2017
Plant Continuous Improvement Manager, Corporate RT and TPM Practitioner, Azusa, CA Private Brands Division (Divested to TreeHouse Foods, Inc. on 2/1/2016) Selected to assist in turnaround of struggling recently acquired Private Brands Division of ConAgra Foods. Implementing JIPM TPM centered improvement processes and Reliability Technology productivity acceleration processes in Private Brands flagship factory. Responsible for creating high performance, world class manufacturing work culture to achieve outstanding business results. Accountable for deployment strategy & tactics, standards & best practice implementation, and critical improvement interventions.
• Quality Excellence – Led product contamination intervention. Determined ingredient prepping and dispensing practices to be root cause and defined best practices. Retooled and trained Operators and Leadership. Reduced incidents per month by 85% in 5 months. Reduced consumer complaints to zero. Most dramatic sustained improvement in plant history. Received commendation and recognition from major customer account.
• Quality Excellence – Eliminated product defect issue with major account. Excessive force was required to remove package lid due to plastic adhesion. Determined induction sealing to be root cause. Defined best practice and settings for optimum seal integrity. Eliminated supply voltage variation. Added cap removal torque QA measurement. Implemented centerline audit to monitor and maintain settings. Drove Consumer Complaints to zero and maintained at zero in forward years.
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• Quality Excellence, Process Capability – Designed and conducted first ever Basic Statistics and Statistical Process Control Seminar in partnership with Azusa Pacific University for Plant Leadership Team and Supervisors as foundational education for yield loss reduction effort. Instruction emphasized TQM tools. Program targeted 1% yield improvement and netted $600,000/yr./line savings.
• Reliability Excellence – Solved reliability issues of recently installed packaging system by implementing process setup and centerline management system improving yield and increasing throughput 53%.
• Organization Excellence – Solved acute staffing shortage that restricted production capacity and order fulfillment. Improved hiring rate 400% resulting in 112 new employees added to roster in 3 months.
• Organization Excellence – Defined and launched Continual Skills Development center of expertise in plant to address skill related losses.
CONAGRA FOODS INC 2010 - 2015
Corporate Manager, Continuous Improvement Program, Oakdale, CA Shelf Stable/Grocery Division
Invited by ConAgra Foods to lead deployment of advanced specialized practices for optimizing manufacturing (P&G Reliability Technology (RT), and JIPM TPM). Coach and confidante to SVPs, Directors, Engineering Leaders, Platform Leaders, Pillar Leaders and Plant Managers on optimization plan execution. Responsible for consultation, standards, RT analytics, and qualification of corporate and plant resources on use of RT and TPM methodologies.
• Quality Excellence – Chartered and led Kaizen team to reduce wastewater discharge by 50% in California factory. Averted plant shutdown. Received Sustainable Development Project of the Year recognition by ConAgra.
• Quality Excellence – Chartered and led Kaizen team to reduce product over-pack by 25% by restoring filler bowl level control to OEM condition and disciplined setup and centerline auditing.
• Quality Excellence – Chartered and led Kaizen team to reduce line stops by 75% by balancing upstream empty can conveyor speeds and surge pressure.
• Organization Excellence – Implemented Continuous Improvement processes (AM, PM, FI, EM) and metrics in Consumer Foods division to eliminate losses, increase throughput, build technical mastery & deliver cost reduction targets.
• Reliability Excellence – Internal Consultant for RT Systems, Tools and Processes – Led implementation of P&G licensed RT methodology in Consumer Foods Division. Designed deployment strategy and led implementation in 10 factories in North America increasing efficiency 10%, increasing throughput 17%, lowering costs $10 million per year. THE PROCTER & GAMBLE COMPANY 2006 - 2010
Program General Manager, Business Integration, Woodland Hills, CA Global Supply Network Operations
Led merger and integration of North America operations, including regional general offices and re-design of supply network operations, for $4.8 billion salon and beauty care products company acquired by P&G.
• Organization Excellence – Integrated operations and established several global best-in-class processes setting records for excellence in SAP Cutover and integration of complex business systems. Optimizations saved $2 million per year.
• Organization Excellence – Merged two regional general offices into one improving customer service levels and reducing annual expense from $17 million to $9 million.
• Supply Chain Excellence – Redesigned operations and reduced regional distribution centers from 5 to 2, improving order fulfillment and reducing annual operating costs by $12 million. THE PROCTER & GAMBLE COMPANY 2003 - 2006
Collective Bargaining Agreement (CBA) Arbitration / Supply Chain Operations Leader, Avenel, NJ Chemical Division
Led collective bargaining and labor relations for unionized chemical plant manufacturing fabric and home care, chemicals, and industrial fragrances. Directed organization effectiveness in a business governed by GMP, Haz. Mat., and DEA regulations. Corporate point of contact for labor and collective agreement matters. Arbitrator and labor contract negotiator.
• Organization Excellence – Led negotiations for three-year CBA for wages and health care plan redesign, persuading five unions to adopt a comprehensive health plan versus fragmented local plans. CBA increased employee contribution from 17% to 25% per year and in return nearly doubled health care benefits and coverage, and put wages on a glide path to reflect industry levels by reducing entry level wage 12% with no increases during life of the CBA, limiting increase in year one to lump sum payment, and containing wage increases to 2.75% per year for remainder of CBA. THE PROCTER & GAMBLE COMPANY 1994 - 2003
Plant Leader – Strategic Site Expansion, TPM Implementation, Anaheim, CA Food and Beverage Division
Led manufacturing for FDA regulated beverage product from sourcing study, expansion design, and startup through engineering enhancement and continuous improvement (TPM). Directed construction and expansion startup, grew AA Bracamonte Page 3
engineering and construction capability, improved QA processes, initiative delivery, production planning, and finished product logistics. Selected as one of seven founding TPM Internal Consultants at P&G. Inducted into Rewards of Leadership program (Top 5% managers).
Supply Network Operations Achievements
• Implemented plant wide Continuous Improvement process (TPM) netting savings exceeding $350,000 in first 6 months. Recruited to support Food & Beverage Division as TPM Internal Consultant.
• On-loan to Brand Team to improve shelf presence of new products with major supermarket. Work Process Improvement netted 75% reduction in out-of-stocks. Resulted in a 30% increase in promotion orders, 7% increase in overall sales. Engineering Systems and Project Management Achievements
• Achieved first ever “vertical startup” of complex production process in P&G history. Validated Global Startup Management Methodology (GSUMM) for company. Reduced startup curve from 6+ months to < 1 month. Reduced factory expansion project costs from $51 to $48 million, tripled physical size, and doubled capacity with no plant shutdown or lost production.
• Negotiated $10 million local and state incentives package consisting of tax rebates, training support, fee waivers and discounted utility rates.
• Awarded Senior Management commendation.
THE PROCTER & GAMBLE COMPANY 1991 - 1994
Plant Leader – Turnaround, Operations, Budapest, Hungary Paper and Disposables Division
Invited to consider then selected to Lead operation, integration, turnaround, startup and expansion of factory in Eastern Europe. Applied engineering and project management expertise in testing, new product scale-up, and production system startup to develop and lead all aspects of manufacturing operation for two product lines.
• Quality Excellence – Employed TQM process capability tools to significantly improve product and package quality. Defined and implemented safe practices to eliminate serious injuries.
• Manufacturing Excellence – Integrated P&G Eastern European Joint Venture company tripling capacity for market.
• New Product Introduction – Developed three new products and launched two.
• Organization Excellence – Hired and developed managers, staff, contractors and regional resources, lowering costs and ultimately achieving manufacturing and engineering self-sufficiency in Eastern Europe. EDUCATION
Dual Degree – B.S. Mechanical Engineering (ME), and B.S. Materials Science & Engineering (MSE) University of California, Berkeley, CA
GRADUATE AND ADDITIONAL EDUCATION
Harvard School of Law – Program on Negotiation
University of Tennessee Graduate School of Management – Total Quality Management (TQM) UCLA Anderson Graduate School of Management – Engineering and Management American Management Association – Program Management, Project Management AWARDS AND RECOGNITION
Sustainable Project of the Year – Nominated ConAgra Foods Product Supply Recognition Shares Stock Grant – P&G Commendation for Business Building Achievements Rewards of Leadership Appointment – Inducted P&G Key Manager Stock Options STAR Appointment – Inducted P&G Key Manager Achievement Rewards IDRC Council Award for Innovative Development of Industrial Property (CoreNet Global) CERTIFICATIONS
Total Quality Management (TQM) – Certified Graduate Practitioner Thermal Processing and Container Closure Evaluation Process Control School (FDA 21 CFR 108, 113, 114, & USDA-FSIS) – Valedictorian – Chapman University, CA – Certified Supervisor P&G Total Productive Maintenance (TPM) – Global Internal Consultant P&G Program Management Certification – Master Practitioner P&G HR MBA II Certification – Practitioner Managing Business Accounts P&G Labor Relations, Arbitration, Collective Bargaining, HR – Master Practitioner
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