A versatile engineering manager with 20 years' managerial experience in designing and manufacturing new products and productivity improvement in consumer, pharmaceutical and electronics industries. Created products that have sold more than $600 million with gross margins of up to 58%. Developed and implemented cost-saving innovations that have resulted in savings of more than $110 million.
Expertise includes outstanding product and process development, staff leadership and development, project management, strategic planning, operations management, and budgeting skills. Additional strengths include strong technical abilities in mechanical design and root-cause analysis.
Zebra Technologies Corporation, Vernon Hills, Illinois 2002-2007
Engineering Manager, Warwick, Rhode Island
Led 12 engineers and technicians in the development and manufacture of wireless handheld printers utilizing 32-bit processors, programmable logic devices (CPLD/PIC), network (802.11 WLAN) and Bluetooth radios for the largest specialty printing company serving the automotive, pharmaceutical, postal, medical, financial, retail distribution, warehousing, defense, transportation and shipping industries with sales of more than $700 million.
- Provided operations input to new product introductions (NPI) regarding DFx on 16 new products. Drove the pilot build process and design corrective actions. Led all divisions in revenue generation from new products.
- Developed and launched a new printer family that generated a 20% sales increase.
- Managed in-circuit, functional and life tests that improved a first-pass yield by 30%, saving $1.5 million annually.
- Developed a vision-guided, robotic assembly system that reduced costs by $200,000 annually.
- Transferred a $70 million manufacturing operation from Rhode Island to California.
- Led a cross-functional team in developing an automated business process for customized configuration requests by field sales. Processed 100-150 error-free requests annually.
NutraMax Products, Inc., Gloucester, Massachusetts 2000-2002
Engineering Director, Brockton, Massachusetts
Developed new pharmaceutical and nutraceutical products along with processes and packaging for a privately owned, private label pharmaceutical manufacturer with $200 million in revenues.
- Created new products that generated $5-8 million in new business following Good Manufacturing Practices (GMP).
- Developed and managed a $1.5 million capital plan for improving operations and cost of goods.
- Validated new equipment and processes that complied with FDA and contract customer requirements.
Hasbro, Inc., Pawtucket, Rhode Island 1998-2000
Engineering Manager, Beverly, Massachusetts
Designed high-volume, handheld consumer electronic products for worldwide manufacture and distribution for a leading toy and game manufacturer with $3.1 billion in revenues.
- Developed 30 software and electronic packaging projects that generated $150 million in annual sales with gross margins of 58%.
- Led the coordination of engineering, prototype development and beta testing with the company's R&D departments in the U.S., Asia and Europe.
- Managed a team of 12 new and experienced engineers in the design of $150 million in new products, representing 75 SKUs.
- Completed all new products ahead of schedule by 16%.
E. Rosen Company, Pawtucket, Rhode Island 1995-1998
Managed process and facilities engineering for a privately held $75 million candy and giftware company supporting five locations in Rhode Island and Massachusetts.
- Designed and installed a complete continuous sanitary thermal process plant that manufactured 18 million pounds of jelly beans annually, improving production yield by 100%.
- Tied manufacturing processes into new product development, improving the success rate of new product launches by 70%.
- Designed custom tooling and processes for new products in compliance with FDA regulations.
- Designed and managed the construction of new corporate offices as well as manufacturing and distribution facilities. Coordinated architectural, contractor and city planning resources to complete construction on schedule and within budget.
- Designed and installed an automated packaging line with 14 pick and place units and a walking beam, reducing cost of goods by 50%.
- Designed and installed chilled water and compressed air systems, partnering with a local utility company. The project budget of $500,000 was offset by utility rebates of $250,000. Realized annual savings in electricity costs of $100,000 and eliminated frequent production stoppages.
Lisa Lee Creations, New Haven, Connecticut 1994-1995
Director of Operations
Managed scheduling, manufacturing, packaging and distribution for a $10 million privately held gold and silver jewelry design and manufacturing company.
- Eliminated a $1 million delinquent order backlog by:
- Increasing plant output while reducing costs 15%.
- Implementing quality procedures and reducing rejects, rework and returns.
- Developing critical vendor resources.
- Successfully fulfilled the first order for a cable distribution channel (QVC), creating a new market opportunity.
Crystal Brands, Inc., Pawtucket/East Providence, Rhode Island 1987-1994
Formerly Trifari Division of Hallmark Cards
Engineering Manager (1990-1994)
Managed manufacturing, industrial, facilities and compliance engineering for a leading fashion jewelry design and manufacturing company with sites in the continental U.S. and Puerto Rico as well as sales of $350 million.
- Managed a staff of 32 in all engineering disciplines and a budget of $10 million. Streamlined plants and downsized staff by 36% while maintaining service levels.
- Improved safety and environmental compliance for one offshore and three domestic facilities. Designed and installed wastewater treatment plants that removed precious and heavy metals while controlling the pH. Achieved zero discharge in 75% of the processes by recycling treated water.
- Reduced cost of goods sold by more than $750,000 annually.
- Implemented lean manufacturing, successfully transferring outsourced work in-house.
Senior Mechanical Engineer, Trifari (1987-1990)
- Developed and implemented continuous improvement programs, saving more than $300,000 annually.
- Developed and introduced into production 500-600 new SKUs annually.
- Developed and implemented custom packaging equipment improving efficiencies by 60%.
Hubbell, Inc., Orange, Connecticut 1984-1987
Senior Mechanical Engineer, Stonington, Connecticut
Managed manufacturing and industrial engineering for a $40 million division of an $800 million electrical devices and lighting manufacturing company.
- Developed nine new electrical products along with tooling and processes complying with UL/CSA safety standards.
- Implemented a capital program of $1 million, generating $300,000 in savings annually.
- Installed cellular manufacturing consisting of CNC and multi-spindle screw machines, an automated custom-designed assembly machine, and automated packaging. Reduced cost of goods by 15-20% for a line of 18 SKUs.
- Developed and installed custom assembly equipment, automating highly labor intensive and strenuous operations. The process became safer, more productive and consistent.
- Developed a three-five year strategic operations plan in support of new products.
Schrafft Candy Company, Boston, Massachusetts 1983-1984
Led the transfer and upgrade of production lines, valued at $5 million, from the New York and Texas facilities into the Boston facility for a $200 million, 135-year old candy manufacturing company.
Roger Williams University, Bristol, Rhode Island
Bachelor of Science, Mechanical Engineering
United States Coast Guard Academy, New London, Connecticut
Bachelor of Science, Economics/Management
Other Courses: Pro/E, Facilitating for Results, Manufacturing Resource Planning, ISO 9000, HALT/HASS Testing and Design for Six Sigma
Computer proficient: IBM-PC, MS Office, AutoCAD, Pro/E
International Management Council (IMC), Past President
Society of Plastics Engineers
American Society for Quality