Develop Manufacturing Options for Startup of fermented beverage in Southeastern US (2017)
- Provide methods to quantify business opportunity, Develop process flow and layout to maximize efficiency and best practices
- Provide equipment schedule and preliminary capital investment estimates for owner
Provide in-depth Feasibility study of Cultured Dairy Product Plant in Stockton CA (2017)
- Develop business plan with client to include product range, volume and profitability goals, capital expenditure expectations
- Create various tools to model growth, capacity flow rates, staffing to support business plan
- Develop capital plan, Project Management timeline Gantt charts, Autocad layouts, equipment schedules
- Determine wastewater capacity, recommended flow volume to commit.
Design and Define self-manufacturing strategy for Concentrated Chai product in North East (2017)
- Define process flows, develop product specifications, critical control parameters
- Develop with client production build to support supply chain requirements of five year business plan
- Create 'just-in-time capital expenditure schedule to minimize capital, while supporting planned volume
- Provide guidance of facility requirements, plant layouts on Autocad, project timeline in MS Project
Provide Manufacturing options for cultured dairy business in New Hampshire (July 2014- Dec 2016)
- Evaluate existing business, growth plans and various facility options
- Provide decision matrix tool to decide best overall fit for business
- Develop process flow and layout to maximize efficiency and best practices
- Provide equipment schedule and preliminary capital investment estimates for owner
- Provide preliminary flow schematics for process engineers to execute
Productivity improvement and KPI implementation of Snack food plant in Texas (May 2014)
- Following plant layout design of new plant, develop key areas of productivity improvement in new plant
- Work with plant management to develop measurable criteria for performance improvement
- Provide working data collection systems with Dashboard for management visibility
Design, Develop layout and process flow for Dairy Product plant in Maine (2014-2016)
- Develop business plan of capacity required
- Develop equipment schedule to support business plan
- Design plant layout to maximize efficiency, lowest losses
- Recommend equipment to be procured; travel with Principal to auction
- Assist in installation of process piping and packaging lines
- Startup of the lines with no business interruption
Start up of RTE meal kit business (2013-2014)
- Develop Bill of Materials, Capacity Plan, packaging systems
- Qualify Co-manufacturer for feasibility, quality systems,
- Develop packaging and supply chain protocols
- Specify equipment, design packaging line for different plant,
- Layout new line for self-manufacturing plant. Install, implement with no business interruption
Install tube packaging line in Yogurt plant in Ireland (2013)
- Source used v/f/f/s filling machine, develop specifications for packaging materials
- Design plant facility for installation, Draw CAD layouts coordinate process and facility modifications
- Coordinate material suppliers of primary and secondary packaging solutions
- Facilitate project from concept to startup
Develop Manufacturing options and feasibility steps for natural vitamin supplement manufacturer
(2012-2014)
- Evaluate current methods, capacities, bottlenecks; compare with company vision for growth
- Develop innovative manufacturing schemes to support growing business with greater efficiencies
- Design new process systems to support 5X growth; install new process and mechanical systems; startup
- Design new plant with cGMP compliance for Tote Blending, compaction, tableting and bottling lines
- Design / install new order fulfillment system for 220 sku product distribution
- Develop and implement Key Performance Indicator program to track vital operations; built Dashboard
Strategic Development of Manufacturing and Supply Chain of a US startup confections company
(2011-2014)
- Develop models to forecast ingredient usage, manufacturing locations, distribution of new brand of candy
- Provide coordination and leadership from laboratory trials to commercialization
- Initiate the development of business systems to support startup and industrialization
Plant designs of (3) Homestead Dairy / Yogurt Plants in NH, Vermont and Indiana (Spring 2011
to current)
- Provide process flow charts, capacity analysis, plant layout on CAD, potential used equipment sources
- Develop flow schematic diagrams, for product, utilities and packaging systems
- Troubleshoot new installation of HTST, develop sanitation protocols
Assessment of NE Cheese company for investment firm (Spring 2011)
- Develop capacity and bottleneck analysis, provide capital expenditure estimate for growth plans
Assessment of large Private Label manufacturer for investment firm (2010)
- Provide capacity analysis of current operations from information
- Develop bottleneck analysis of future growth, alternative technologies
- Recommend action plans for improved productivity, capacity without capital
Plant Expansion Design for Dairy Plant in New England (2010-Current)
- Provide Capacity Analysis of existing operations, compare to future sales forecast
- Design flow of future plant to maximize productivity
- Layout new plant concept in scale, revise to meet all objectives
- Develop equipment schedule for expansion; define specifications; procure
New Dairy/Beverage Plant design concept (2010)
- Help define business objectives, product types, annual volumes
- Develop process flows, specific equipment requirements
- Preliminary plant layout concepts
- Develop initial critical equipment schedule for off-shore procurement
- Lead equipment search, RFQ, receive and evaluate quotes
Long Range Plan development, Capacity Expansion of Baking Mix Operation in New Hampshire
(2008-2010)
- Assess strategic 5 year plan, Develop Manufacturing Capacity Requirements
- Develop Capital Plan to meet Sales Forecast; Provide comparative analysis of technologies
- Implement Plant layout and design, install equipment
- From concept to production and shipment -4 months
- Continued support of Productivity Improvement, cost analysis, Operation Management
Plant Expansion of Organic Yogurt Plant in Ireland (2005-2009)
- Performed 5 year Capital Plan, Capacity Analysis
- Managed $5.2 Million project- 500% Growth in capacity
- Began Construction March 1; In production June 15
- Continuing support of Productivity improvement
Cost Improvement analysis in Tofu Factory in Massachusetts (2007)
- Performed Facility analysis, identify key cost factors
- Recommended action plan for $2+ million savings
Packaging Automation for cost savings at Greek Yogurt plant in NYC
- Evaluate current systems, prioritize aspects to automate
- Research used equipment inventories in US for best fit
- Develop capital plan, ROI model, procure, install
Total Plant optimization of Natural Yogurt plant in California (2004-2008)
- Perform 'Bottleneck Analysis' of total operation (milk source to Distribution System)
- Purchased adjacent facility; convert to raw processing building
- Optimized existing facility, upgrade refrigeration, infrastructure
- Provided 300% output potential from same 'envelope'
- Modified packaging systems to support West Coast distribution of East Coast brand
Waste Water optimization of Yogurt Plant in New Hampshire
- Define parameters for compliance with local authorities, evaluate options
- Optimize existing system while building new anaerobic plant with innovative drain diverts
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