Operations Manufacturing Leader with Engineering experience

GREGG GECALE

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

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

www.linkedin.com/in/gregggecale

*****.******@*****.***

Experience

Berje Inc.

Carteret, NJ

*/****-*/****

Director of Production Operations, Carteret Plant

Oversaw the daily production operations of fragrance and essential oil processing that represented sales of over $190 million per year including safety, shipping & receiving, and maintenance departments with over 65+ employees

Increased efficiency at the site by reorganizing order flow and collaborating with sales and planning departments to meet OTIF performance of 92.5%

Transitioned the facility to a permanent two shift operation in response to COVID and added additional personnel to increase capacity and productivity on the second shift

Shiseido

East Windsor, NJ

3/2017-6/2020

Manufacturing Manager, Shiseido Americas

Manage high volume manufacturing operations of over 400 skincare and cosmetic products per month with 4 supervisors and 50+ indirect reports

Consolidated two manufacturing sites to increase capacity by 31%. Advise in the design and construction of facility expansion of the manufacturing department

sAttained an improvement of 12.5% in productivity over the last year by implementing six sigma lean methodologies, visual management, 5S activities, and employee engagement initiatives that reduced changeover times and improved schedule attainment from 83% to 97%

Instituted a safety program resulting in a 40% improvement in safety performance

Developed and implemented an employee capability matrix, and provided cross functional training that resulted in 30% reduction in overtime savings of $150k annually

Assess key performance indicators and champion improvement projects that support company KPIs such as safety, quality, productivity, waste reduction and GMP

Elementis Specialties

Jersey City, NJ

8/2014-2/2017

Production Manager, Jersey City Plant

Directed 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).

Implemented 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

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

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

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, and GMP standards

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

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.

Led safety, environmental, customer complaints, and quality incident investigations to define corrective and preventative actions. Responsible for ensuring 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

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%

6/2007 - 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%

Education

Cornell University

New York, NY

8/2019 - Present

Executive MBA, Johnson Graduate School of Management

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),

Lean Manufacturing Leader Training (DuPont)

PHA Leader Trained (ABS Consulting Group)

ISO9001:2008 Auditor Trained (2015)

Certified in DOT, IATA, & IMDG (2015)

First Aid Responder Trained (2018)

Skills

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

Working knowledge of SAP, JDE, Continuous Improvement, Statistical Process Control, GMP, SQF, HACCP

Volunteering

Engineering Mentor for MentorNet, the E-Mentoring Network for Diversity in Engineering and Science, Habit For Humanity, United Way, DuPont Career Fair Recruiter, Clear Into the Future Volunteer

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