Beauty Care Manufacturer of Owned Brands and Private Label - $1.6B Revenue
new plant startup
Lean Member of Leadership Team responsible for startup of $90M “Greenfield” manufacturing plant and Pilot Lean facility.
Key role in site vision, hiring, design of HR policies, work procedures, and creation of culture designed to encourage high-performing work teams in a low-hierarchy organization.
Trained all employees, corporate global operations leadership, and select suppliers in Lean concepts and implementation of 5S, Operational Effectiveness, Flow, Material Movement, Quality, and Employee Involvement.
transitions & systems
Successfully transitioned 658 branded and private label SKUs including relaxers, shampoos, conditioners, styling aids, splashes, lotions, and kits.
Implemented FDA-regulated OTC production and Flammable production and supported SAP blueprinting and implementation.
process management tools
Created communication board/automated hourly tracking system for all lines to track daily progress to goal, real-time OEE, and minutes lost.
Designed and implemented intranet-based downtime tracking system for filling, preweigh, and compounding.
Implemented internal pull system to dramatically increase visual management through the value stream.
Managed 33 production lines including bottle, jar, tube, and pouch filling, as well as kit assembly, producing 16M units per month with a $7M annual budget.
Led 10 direct reports including 3 Cell Managers, Lean Coordinator, 3 Shift Leaders, Scheduler, 2 Production Clerks, and 200 indirect reports including Machine Specialists, Production Specialists, Waste Handlers, and Shift Clerks plus up to 280 temporary employees.