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Production Operations Manager

Hopewell Junction, New York, 12533, United States
January 19, 2017

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Paul Whalen

* ********* *****

Hopewell Junction, NY 12533



Accomplished management professional with extensive experience in varied manufacturing/warehousing environments. Proven competence in leading diverse teams in dynamic work environments. Recognized ability to effectively communicate across all organizational levels. Notable capabilities include:

Project Management New Product Development Employee Motivation

Process Analysis/Improvement Quality Assurance LEAN Practices


ATI Flat Rolled Products, Waterbury, Connecticut December 2015 – July 2016

Operations Supervisor

Contract position through Technipower, (Roswell Ga.) for client Allegheny Technologies Incorporated, (Flat Rolled Products Division) in Waterbury Ct. Worked with management team during company “lock-out” of United Steel Workers union employees during labor negotiations of new contract. Provided oversight for production efforts of Industrial Strike Staffing Employees provided by Strom Engineering Corporation (Minnetonka, MN) in a cold-rolling stainless steel mill. Responsibilities included prep-line, rolling operations, annealing operations, leveling operations and Quality Assurance throughout all processes. Reported directly to Plant Operations Manager.


● Successfully trained and mentored temporary non-union employees working 6 12 hour shifts on company procedures and safety practices.

● Achieved 80% production capacity goals with 90% acceptable quality inspections during CPP (Customer Protection Plan).

● Managed return transition from temporary workforce to Union employees under challenging and hostile conditions.

● Created plan to monitor usage hours of backing rolls on Sendzimir Mill to improve dimensional stability.

Schatz Bearing Corporation, Poughkeepsie, New York March 2015 – April 2015

Manufacturing Consultant

Contract position working with management team of an AS9100, ISO 9001:2008 certified specialty ball bearing manufacturer on evaluating employee performance in final assembly. Verified company SOP’s were being followed and counselled assemblers who were not in compliance. Improved communications with manufacturing to insure timely delivery of components to achieve targeted OTD’s. Reviewed scrap rates, conducted RCA’s and developed solutions. Refined metrics for employee performance evaluations.


● Reviewed and updated job procedures to reflect changes in specifications or quality requirements.

● Established more direct line of communication with manufacturing reducing supply delays by 20%

● Initiated singular rather than cellular employee evaluation system resulting in more accurate reporting.

Flagship Converters Inc., Danbury Connecticut September 2014 – December 2014

Operations Manager

Contract position tasked with evaluating and renewing plant policies and procedures. Reviewed and updated SOP’s to improve material flow. Defined new QA requirements. Trained and directed supervisory staff on establishing and maintaining a positive factory environment. Developed and implemented program to monitor machine usage to evaluate preventative maintenance requirements. Coordinated and approved vacation requests to ensure continuous operations.


● Reviewed and updated plant policies and SOP’s.

● Created framework for new quality policy (work in progress).

● Collaborated with maintenance staff on developing structured preventative maintenance program (work in progress).

Brewster Plastics Inc., Patterson, New York October 2010-June 2014

Production Manager

Managed all production operations of 90,000 sq. ft. ISO 9001:2008 Certified Plastic Injection Molding manufacturer. Provided Production Planning for 3 shift molding and assembly operations serving customers in the automotive, medical, pharmaceutical and food manufacturing industries. Developed and maintained Managed Inventory Systems based on customer demand. Reviewed new jobs for best allocation of resources and developed operating procedures for each. Designed New Hire Training Program consistent with ISO Training Matrix requirements. Implemented Cross Training program for existing employees. Responsible for 12 Internal ISO audits/Process Owner Reports annually. Worked with HR and QC managers on employee performance issues.


● Developed and maintained Managed Inventory System to reduce inventory costs and product delivery times.

● Planned and implemented testing schedule for 30% demand increase of largest customer’s new acquisition.

● Rebalanced labor allocations between shifts to reduce set-up frequency and increase production capacity.

POP Displays, Yonkers, New York August 2008-February 2009

Plant Manager, 2nd Shift

Managed the production/assembly/warehousing efforts of 435,000 sq. ft. plastic injection molding display manufacturer. Provided oversight for 175 union and non-union employees on 2nd shift of 24 hour manufacturing facility. Coordinated with 1st and 3rd shift Plant Managers in creation of production schedules, labor allocations and material requirements. Member of Implementation Team for LEAN Cellular Manufacturing model serving large scale customers including Walmart, Maybelline, Home Depot and Phillip Morris. Assigned and documented shop orders to First Line Leads and monitored progress to assure production goals. Reviewed SOP’s and presented recommendations for improved efficiencies to management. Collaborated with QC team to insure strict quality standards were maintained. Responsible for training of new employees. Conducted performance reviews and provided necessary counseling and training where indicated.


● Successfully identified, recruited and trained candidates for 2nd shift Leadership Team from existing employee roster.

● Led newly formed Team to develop new operating practices reducing “idle time” resulting in labor efficiency increase of 15%.

● Collaborated with Planning Department to increase on-time shop order completion to over 98%.

● Served on 16 member Facility Health and Safety Board.

The Mines Press, Cortlandt Manor, New York April 2002-April 2008

Plant Manager

Managed the production, receiving/warehousing/shipping efforts of 110,000 sq. ft. printing plant. Planned schedules for 5 diverse departments with seven supervisors and 75 employees. Ensured operational efficiency and cost reduction through optimum utilization of resources and continual improvement of methods and procedures. Directed work priorities and timelines and adjusted resources to assure goals were met. Coached and mentored supervisors toward “Team Mentality” through direct reports and production meetings. Coordinated print production work and fulfillment schedules for vendor work. Conducted performance evaluations for production staff and set future performance goals. Worked with Operations and Finance Managers to develop annual budgets.


● Led the development and initiation of comprehensive preventative maintenance program resulting in 15% reduced downtime for major equipment.

● Designed and implemented “Discreet Issue” inventory system to monitor and eliminate sources of waste resulting in lower operating expenses and more accurate cycle counts.

● Planned production/proofing schedules for fifth division without additional staffing.


State University of New York at Geneseo

Bachelor of Arts – Communications


CRC, Intuitive, TMM, Epicor, Tandem/Walker MRP/WMS Systems

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