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Plant Manager Independent Consultant

Location:
Ann Arbor, MI
Posted:
December 13, 2021

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Resume:

VIVEK GARG Ann Arbor, MI ***** 734-***-**** adpm4w@r.postjobfree.com

GLOBAL MANUFACTURING OPERATIONS LEADER

Operational Efficiency Expert Turnaround Vision, Strategy & Execution International Experience

Proven Success in Both Small & Large Organizations

Successfully managed P&L up to $100 M delivering high shareholder value by growing revenue and effecting substantial cost savings. Efficiency-focused Operations and Manufacturing Leader offering more than 20 years’ experience. Broad suites of global operation and manufacturing experience including procurement, manufacturing/distribution, quality assurance, strategic sourcing, logistics, transportation, inventory management, and continuous improvement initiatives that delivered substantial 6- to 7-figure cost savings and operational improvements. Managed manufacturing plants for Plastics, Flexible / Rigid plastics packaging, raw materials for the plastics and filament yarn/fiber industries (PET polymer and fibers including the chemical process of polymerization) and building materials thus bringing a very broad outlook for problem solving in any industry leveraging the cross-industry experience gained over time. Managed union and non-union plants. Managed the construction of 3 polyester plants.

Transformative leader instrumental in building and managing teams of up to 330 staff. Extensive multicultural experience directing manufacturing operations in United States, Mexico, Asia and Africa. Leverages deep knowledge in the plastics, chemical processing, food grade packaging, and textiles industries, underpinned by an uncanny ability to rapidly absorb and understand manufacturing processes, and generate robust solutions for scalable business growth.

Natural Communicator adept at breaking down cultural barriers to inspire accountability and lead high-potential individuals into cohesive, high-performance teams through ongoing training, hands-on involvement, and clear communication of expectations and goals.

Leverages dynamic project management skills with extensive operational and manufacturing experience working with executive leaders to identify, evaluate, select, and execute the right strategies and initiatives that achieve value-building goals. Applies strong analytical problem-solving skills with sharp focus on improving bottom-line profitability.

KEY AREAS OF EXPERTISE

Operational Restructuring

Cross-Functional Team Leadership

Change Management

Crisis & Turnaround Management

Budgeting / Cost Control

Risk Management QA/QC

Production Capacity & Logistics Planning

Cross-Cultural Communication

Talent Development

KPI Identification / Compliance

Continuous Process Improvement

Project Management

Plant Construction Management

Automation/BU Turnaround

Flexible and Rigid Packaging

ISO Accreditation

Extrusion / Injection and blow molding/ Plastics / PET / PP

Manufacturing Management

Operations Strategy & Execution

P&L

Product Costing

Strategic Relationship Building

Supplier Relations

High-Impact Negotiations

Enterprise Resource Planning (ERP)

Union / Non-Union

OPERATIONS & MANUFACTURING LEADERSHIP EXPERIENCE

PMC Global Inc./Zenith Global LLC Howell, MI August 2020- May 2021

OPERATIONS CONSULTANT

Operations Consultant at Zenith Global LLC (Injection Stretch Blow Molding plant for the production of PET jars and bottles), Howell, MI to streamline inventory control, inventory reconciliation, warehouse management system, HACCP review and preparedness for audit, Capex reviews and reconciliation, QMS, SQF/BRC quality systems build, implementation and audit to get certification, product costing, process streamlining, new expansions at current and other locations, ERP selection and implementation. Other requirements as they come up.

PMC Global Inc./Direct Pack East North Carolina May 2017 – December 2018

GENERAL MANAGER

Direct Pack is a manufacturer of Rigid Plastic Packaging for the food industry through extrusion of PET and PP sheets that are then thermoformed, trimmed, packed and supplied to fresh produce, ready to eat, restaurants, and grocery packing customers. Production capacity of 80,000 lbs. per day extruded sheet and 750,000 containers/lids per day resulting into 30 full container loads of product per month. An additional 125 full containers per month were imported and distributed.

Re-hired by PMC. Held P&L responsibility for $30M in manufactured product and imports/distribution. Managed 60 employees across Manufacturing and Warehousing. Reported to: President

Reduced variances from $100 K range to less than $5K in monthly inventory by implementing effective daily and monthly reports for accurate tracking of production and inventory

Improved make vs. buy decision by redesigning costing system for a more accurate allocation of fixed costs

Achieved score of 905/1000 on AIB audit by implementing robust SOPs. Implemented HACCP and GMP systems

Freed up $500 K capital by liquidating slow moving, obsolete inventory, and effective FIFO

Flex Americas SA DE CV Mexico Feb 2014 – Dec 2016

Senior VP/BUSINESS HEAD/GENERAL MANAGER

Flex Americas manufactures PET Films for Flexible packaging mainly in the food industry. Daily production of 150 metric tons of film in a 24/7/365 operation in two plants having extrusion/stretching, slitting, metallizing, holographic film, AlOx and coating processes.

Held full P&L responsibility for $100M and managed 330 employees across production, manufacturing, accounting, HR, purchasing, and supply chain and logistics and. Reported to: President

Increased EBITDA by approximately 50% and improved profit margin by 7.2%

Saved $6M annually by importing resins from Asia

Improved efficiency by more than 10% by implementing effective SOPs for machine operation and better equipment maintenance

Added new specialty product to portfolio resulting in sales growth 0f $12M annually

Achieved 33% decrease in WIP materials after improving an organization-wide recycling program

Directed implementation of new quality management systems and updating the existing ISO procedures to ensure continuity and consistency between teams

Improved on-time delivery from 90% to 97%

The facility was unionized. Negotiated with the Union annually along with the HR Manager and a Board Director.

PMC Global Inc./Pozzolana Ghana Ltd. Ghana Feb 2011 – Jan 2014

MANAGING DIRECTOR

The company was producing 10,000 bags of pozzolana per day from calcination and milling of clay. Pozzolana is a cement additive that enhances the strength and longevity of cement and also improves the capability to withstand corrosion in damp or wet environments or for underwater construction.

Re-hired by PMC. Investigated the inconsistency in the quality of a new cement product being manufactured by Pozzolana. Established robust manufacturing processes and resolved coordination issues among teams. Managed 80 employees, a $100K monthly operating budget. Reported to the CFO and Executive VP of PMC Global. P&L responsibility

TDIC Industrial Robot & Protective Covers Michigan Jun 2009 – Feb 2011

INDEPENDENT CONSULTANT

TDIC is a $10 million company manufacturing covers for the robots that are spray painting automobiles to prevent the robots themselves being sprayed with the paint.

Consulted at TDIC to resolve quality issues in the manufacturing process for the robot covers for the automotive industry

Reduced extraneous particles tested from 2000 to less than 5. If a particle drops onto a car during painting, the whole car paint has to be re-worked

Spearheaded ISO 13485 accreditation, including management of external audit processes, and facilitated the update for ISO 9000 that led to increased validation for TDIC as a reliable partner in commercial relationships

PMC Global Inc./Zenith Global LLC Michigan January 2007 – April 2009

VP OPERATIONS

Directed the startup operations for a PET jar manufacturing plant for the food packaging (rigid packaging), including plant design and layout, equipment selection and purchasing, negotiating construction contracts, securing government permits, and establishing warehousing and distributions networks

Selected automated packaging equipment to match the production rates of 6M jars per year, which increased efficiency of the packaging process and reduced labor costs

Managed and monitored injection blow molding machine processes to minimize waste and conserve materials

Participated in the recruitment, interviewing, hiring, and training procedures for new employees

CDI Inc. Illinois 1998 – 2007

CONSULTANT

Durable Packaging: Consulted as VP and COO for Durable Packaging, managing and coordinating a 30-member team in streamlining manufacturing operations in preparation for company sale. Held direct responsibility for a $5M budget

Consulted at Allstate Insurance.

PT Indorama Synthetics Indonesia 1990 – 1998

SENIOR MANUFACTURING MANAGER

Directed and supervised the construction and operation of 2 polyester staple fiber plants for a $60M manufacturing division with accountability for 125 employees. Led multiple technical and operations projects focused on streamlining production trials and processes, maximizing performance/productivity, maintaining consistent quality levels, implemented ISO standards. Participated in interviewing, hiring, and training new employees.

Reliance Industries Ltd. India 1985 – 1990

SENIOR ENGINEER

Managed and supervised the construction and operation of 2 polyester fiber spinning lines and 4 fiber lines for 180 Tons per Day plant. Built up processes and Standard Operating Procedures, recruited and trained employees. Managed the Process Control Department for Spinning and Fiber Lines.

JCT Nylon Division India 1983 – 1985

SHIFT ENGINEER

Managed the complete shift for a Nylon Filament yarn spinning plant.

EDUCATION

Bachelor of Science (BS), Textile Technology Indian Institute of Technology Delhi, India

Two-week training – Small Business Management

OTHER

Technology Skills: Microsoft Project Manager and Microsoft Office Suite (Word, Excel, PowerPoint, Outlook)



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