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Production manager

Location:
Jersey City, New Jersey, United States
Posted:
January 10, 2017

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GREGG GECALE

*** **** ****** **** **, Jersey City, NJ 07302

Cell: (908) ***-****

www.linkedin.com/gregggecale

acx7g7@r.postjobfree.com

Experience

Elementis Specialties

Jersey City, NJ

*/****-*resent

Production Manager, Jersey City Plant

Direct daily manufacturing operations and planning for paint colorants and rheology additives of over 350 active SKU’s including safety, shipping & receiving, human resources, and scheduling with 18 direct reports (union).

Implement Lean Six Sigma methodologies to improve workflow performance, standardize processes, eliminate waste, and execute continuous improvement initiatives. Track operational KPI’s including Yield, OTIF, OEE, unit cost per ton, and inventory cost.

Increase productivity by 5% and produced a cost savings of up to $100M annually while realizing a 10% labor savings of $80M annually by developing an effective scheduling process to meet on-time deliveries. Improve schedule adherence from 78% to 91%.

Lead planning and engineering support launch of new business which generated additional $1MM in sales to the site

Develop and implement rotating training program to ensure a skilled working force and reduction of poor performing employees

International Flavors & Fragrances Inc.

South Brunswick, NJ

3/2014-8/2014

Production Supervisor, Sample Lab Flavors North America

Oversaw the transition of new product development from the creative team to production. Coordinated the daily food chemical manufacturing activities of the North American Flavor Sample Lab and Sample Shipping Area to meet goals for food safety, quality, GMP standards

Managed, develop, and coach direct reports (non-union)- 8 Liquid Compounders, 1 Planner, 1 Team Lead, 1 Shipping Operator, 2 Material Handlers and 2 Temporary employees to ensure a delivery to promise for an average of 130 Sample Lab requests per day

Organized priorities of the Sample Lab request queue for the sales group, creative department, domestic and international affiliates, and external customers to meet on-time performance of 92%

Reduced Sample Shipping costs of hazardous goods by 26% by reducing sample size from 2oz and 4oz containers to multiple 1oz containers

Led initiative to reduce Sample Lab QC rejections by 25% by working with the Technical and Creative group centers to unify liquid compounding instructions from creative through production and maintain inventory of raw materials

Continuous optimization of the Sample Lab’s available equipment and software with the replacement of all bench scales with electronic weight control and transition from IFFMAN software to SAP

DuPont

Field Rotational Program

7/2012-2/2014

Product Team Manager, Fluoroproducts Deepwater, NJ

Coordinated day-to-day activities to meet goals for safety, quality, and productivity for high hazard refrigerant manufacturing processes and shipping area. Managed direct reports (union), 10 chemical operators and 2 clerks, to meet delivery-to-promise goals for 8 domestic and export products

Participated in Supply Chain & DIBM processes to define production goals and customer needs, communicate required transitions & major outages, and maintain a minimum raw material inventory.

Coordinated periodic & physical inventory validation to perpetual SAP R3 inventory records while solving discrepancies and preforming root cause analysis

Worked directly with maintenance organization to ensure that equipment repairs and annual inspections are identified scheduled, and completed on time through Work Management Process

Led safety, environmental, customer complaints and quality incident investigations to define corrective and preventative actions. Responsible for insuring the area stays compliant with NJ TCPA regulations as area TCPA Coordinator

Maintained and monitored KPI’s including weekly Inventory Accuracy, Downtime, Quality, and BOM metrics to meet business goals

Applied Lean, Six Sigma, and DPS tools establishing systems in place to improve Uptime from 50-80% in K-40 Process, delivery-to-promise from 24% to 60% and cycle count metric from 84% to 98%

3/2010-7/2012

Engineering Consultant, DuET Engineering Evaluations & Sustainability Wilmington, DE

Identified technical options, define and model commercial process concepts, estimate manufacturing costs, assess business risk, and prepare preliminary equipment specifications for investment estimates and financial analysis

Optimized operations scheduling of various batch fermentation scenarios for ButamaxTM using SuperPro Designer to reduce turnaround time of equipment use.

Developed Yerkes Tedlar® OR Film additional 25% capacity options using Aspen Custom Modeler

Co-lead Value Accelerator to reduce rework of non-conforming Kalrez® perfluoroelastomer parts at Tralee Park by 12%

Modeled Memphis Oxone® process in Aspen Plus to test and simulate effects of process changes

10/2007 - 2/2010

Manufacturing Technical Engineer, Tedlar® SP Film in Fluoroproducts Division Buffalo, NY

Supervised and led 8 operators (union) in start-up commissioning of new Mix Room during second and third shifts. Wrote procedures and trained operators how to use new Siemens automation for tank batch make ups

Converted pilot plant process to commercial scale utilizing existing primary equipment within two years. Scaled from 20Mkg/month production to 100Mkg/month

Implemented statistical process control charting of key process indicators. Oversaw development of metrics to prioritize and drive continuous improvement efforts

Led $2MM cost savings project through new Siemens vision system that eliminated manual visual inspection of film which reduced scrap by 15%

6/2007 – 10/2007

Quality Engineer, Tedlar® PVF Materials in Fluoroproducts Division Buffalo, NY

Lead root cause analysis and corrective action on over 250 complaints and internal quality failures

Formed teams in efforts to analyze quality issues and provide insight to recommend immediate and systemic process improvements

Identified non-conformance trends and develop technical investigation plans within process assessment

Merck & Co., Inc.

West Point, PA

9/2006 - 6/2007

Validation Engineer, Bio/Sterile Validation in Vaccine Technology & Engineering Division

Updated procedures for validation studies and wrote technical reports that addressed any atypical events for vaccine equipment and instrumentation cleaning/sterilization testing

Collaborated with Quality and Procurement to establish a baseline for gamma irradiated items to meet a sterility assurance level (SAL) of 10-6

Education

Columbia University

New York, NY

9/2002 - 5/2006

B.S. in Chemical Engineering, Minor in Material Science Engineering; focus on Polymer Science

Dean’s List, Regional Alumni Interviewer

Affiliations

American Institute of Chemical Engineers, Society of Hispanic Professional Engineers

Certification & Training

Six Sigma Green Belt Certified (DuPont, 2011)

Lean Manufacturing Leader Training (DuPont, 2012)

PHA Leader Trained (ABS Consulting Group, 2016)

ISO9001:2008 Auditor Trained (2015)

Certified in DOT, IATA, & IMDG (2015)

Trained in all DuPont Production Systems (DPS) and Engineering Engagement for Innovation (EEI ) modules, including Leadership Coaching Dialogue (LCD) workshop

First Aid Responder Trained (2016)

Skills

Proficient in Microsoft Office, Minitab, JMP, AspenPlus, MatLab, VBA Programming, SAP, JDE

Working knowledge of IP21, LabView, Statistical Process Control, MathCad, SuperPro, Visio

Volunteering

Engineering Mentor for MentorNet, the E-Mentoring Network for Diversity in Engineering and Science

DuPont Career Fair Recruiter, Clear Into the Future Volunteer



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