Plant/Operations Manager
Resume:
LEN ZACCAGNINO
New Rochelle, NY 10804 Email: *******@*********.***
PROFILE
Extensive experience in the manufacturing and beverage industry as a Vice President and Director of Operations with a focus on cost efficiencies, productivity, quality, and bottom-line profitability.
COMPETENCIES
• Strategic Planning • Lean Manufacturing
• Production/Logistics • Goal Setting & Performance Metrics
• Facilities Management • Streamlining/Re-Engineering
• Capacity Planning • Continuous Quality Improvement
WORK EXPERIENCE
PEPSI-COLA BOTTLING COMPANY 1985 - 2011
DIRECTOR OF MANUFACTURING, College Point, NY 2007 - 2011
• Directed operations for two plants with 195 employees and annual production of 37 million cases, contributing to $675 million in sales revenue.
• Oversaw key operational functions including plant management, production, capacity planning, facilities management, logistics, and quality assurance.
• Worked in collaboration with sales and marketing to review sales forecasts, combined with historical and seasonal trends to facilitate inventory planning and production scheduling.
• Managed, tracked and controlled an annual operating budget of $38 million.
• Utilized goal setting and performance metrics to encourage team ownership and accountability for bottom-line results.
• Used process/workflow analysis and statistical reports to identify cost drivers.
• Streamlined and re-engineered processes resulting in an increase in production efficiency from 68% to 74%, contributing to approximately $450K in annual revenues.
• Used data collection, analysis and trending to take a proactive versus reactive response to problems and opportunities.
• Achieved a raw material floor/carry list reduction of $1.2 million.
VICE PRESIDENT OF OPERATIONS, Pennsauken, NJ 2002 - 2007
• Directed a workforce of over 230 employees with responsibility for manufacturing, logistics, facilities distribution, vending services, and fleet operations for 160 trucks, trailers and vans.
• Oversaw production to 22 million cases to support $309 million in annual revenues.
• Managed employees in a union environment requiring a collaborative working effort with union officials with participation in collective bargaining.
• Developed and implemented long-term strategic planning, including capacity planning, capital improvements, workforce reductions, cost efficiencies, and continuous quality improvement.
• Implemented self-directed work teams combined with streamlining and re-engineering to achieve lean and efficient staffing, resulting in a 25% headcount reduction.
• Managed fleet operations including maintenance, repairs and overhauls, reducing fleet downtime from an average of 11% to 4%.
• Implemented performance management and Best Practices and cross-functional teams to build consensus and support for positive change and shared goals.
• Increased plant efficiency and output by 7%, contributing to an annual revenue growth of $525K.
• Earned the prestigious Caleb-Bradham Product Award.
LEN ZACCAGNINO Page 2
Resumé (Continued)
WORK EXPERIENCE: (Continued)
DIRECTOR OF MANUFACTURING, College Point, NY 1995 - 2002
• Directed a workforce of 230 employees generating 46 million in annual case production.
• Oversaw key functional areas of responsibility including manufacturing, inventory planning, logistics, distribution, and facilities management.
• Implemented a continuous quality improvement program using performance metrics, resulting in the Caleb-Bardham Award for five out of seven years.
• Key catalyst in the consolidation/merging of two Canada Dry plants and two Pepsi production plants into two major manufacturing facilities.
• Managed key aspects of the consolidation including capacity planning, capital improvement, capital equipment installations, staffing analysis, and workforce transitioning.
• Used facility merger as an opportunity to set-up new process flow, resulting in increased output of 7% and cost reduction of 15%.
PLANT MANAGER, Long Island City, NY 1990 - 1995
• Directed a workforce of 185 employees with annual production of 18.5 million cases, supporting six districts in the New York metro area.
• Managed key operational functions including production, inventory planning, logistics, distribution, and fleet management covering 105 trucks.
• Ran five production lines managing each as a separate P&L to encourage internal competition.
• Used separate P&Ls and internal competition to implement peer mentoring.
• Implemented plant efficiencies and output by 8%, contributing to revenue growth of $600K.
PLANT MANAGER, Brooklyn, NY 1985 - 1990
• Ran all plant operations with a focus on cost efficiencies, productivity, self-directed work teams, lean manufacturing, and bottom-line profitability.
• Ran two production lines and increased plant efficiencies by 8%.
• Key catalyst in the installation of a work order system to track, monitor and report on operational performance.
• Promoted from Production/Maintenance Manager to Plant Manager.
EDUCATION
WESTCHESTER COMMUNITY COLLEGE
Business Management
COMPUTER SKILLS
Microsoft Word, Excel and PowerPoint; P.P.; AS400; Avail/Arete
References available upon request
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