THOMAS V. DEBROCK
SUMMARY
A resourceful and forward-thinking engineering, manufacturing and facilities operations executive with extensive experience in engineering, manufacturing, supply chain, SAP, TPM, CMMS Maintenance, purchasing and procurement, production planning/scheduling, inventory systems, quality systems, negotiations and relationship management. As an enterprising leader utilizing TPM and Lean tools, evaluates new and existing systems and implements redesigned processes and equipment improvements to reduce cost, improve reliability and optimize performance. Works closely with associates to cultivate an environment of mutual respect and honesty, increasing employee participation in company initiatives. A top producer who consistently exceeds business expectations with a goal to increase profitability and decrease costs while increasing responsibilities.
SAP ,Lean, Six Sigma, TPM,CPIM, CSCP, CQA, CQMgr, Quality, Exel, IT, P&L, Supply Chain, CIP, Aseptic, GMP, AIB, FDA
EXPERIENCE
PEPSICO Tropicana Products, Inc Jersey City, New Jersey
Manager, Technical Operations and Engineering,.2000-2009
Held full accountability and P&L responsibility for the Technical Supply Chain facilities operations and engineering of facility, including engineering programs, purchasing and procurement, SAP, TPM, CMMS maintenance, capital spending, refrigeration and utilities, information technology support, safety, security, inventory systems, quality systems and SOX compliance for systems. Served as SAP implementation lead for facility, as well as warehouse management systems super user. Delivered truthful and consistent communications to entire facility labor force, including state of Tropicana business.
Instituted the use of Lean and Six Sigma concepts through TPM ( Total Productive Maintenance) and developed open metric score-carding by shift, day, week, period, and year to involve every individual of labor force while maintaining high-degree of respect for all. Improved relations between management and labor, resulting in open and honest communication environment, full involvement/support of labor on floor for facility initiatives, labor grievances elimination, labor force personnel accepting/performing management functions and 40% increase in labor productivity over three years.
> Flawless execution of the SAP implementation with a systems to systems reconciliation of less than $2.00 on an
inventory of $6,000,000.
> Zero impact to Customers order fulfillment during the SAP implementation
> Reduced facility labor overtime a savings of more than $520,000 per year.
> Improved labor productivity through improved equipment, systems and operations management saving over $450,000.
> Improved facility systems operations reliability from 90% in 2000 to over 99% in 2008.
> Eliminated outbound shipment limitations & increasied systems capacity to 240 trucks per day with a facility annual volume of over 60,000,000 cases.
> Enhanced associate morale and urgency to deliver results.
> Saved 20% in electrical usage while increasing facility refrigerated space 22%, resulting in $100,000 savings per year.
> Developed and built a Capital building expansion that avoided the purchase of $13,000,000 in railcar fleet.
> First Distribution Center to complete Phase 1 TPM (Total Productive Maintenance) in the QTG group of PepsiCo.
PEPSICO - TROPICANA PRODUCTS, INC.Bradenton, Florida
Manager, Contract Manufacturing1995-2000
Oversaw the Contract Manufacturing Supply Chain including negotiations, contracting, procurement, planning, scheduling, process start-ups and qualifications, production, quality, inventory and distribution of Tropicana juice and beverage products at third-party contract manufacturing facilities.
> First Tropicana Pure Premium Orange Juice product in 128 oz plastic format packaged at a third party contract manufacturer. This was the first manufacture and packaging of the Flagship branded product off the main production campus. Reduced go-to-market timing and costs as a result.
> Consolidated the Dole Branded Frozen product line into the Tropicana Frozen product portfolio (Category Sales - $120,000,000/year) at a third party contract manufacturer, saving yield losses and distribution costs of over $3,000,000 annually.
> Held fully accountable for the manufacture, storage and distribution of Twister, Orange Juice from Concentrate and Grapefruit from Concentrate in PET Format. 12,000,000 cases per year at a third party manufacturer.
ADDITIONAL EXPERIENCE
SEAGRAMS -TROPICANA PRODUCTS, INC.
Manager, International Operations, Bradenton, Florida, 1992-1995. Established and managed the European Supply Chain including planning, scheduling, process start-ups and qualifications, manufacturing, port selection and operations, inventory, shipping (ocean going and inland) and distribution of the Tropicana Chilled Product line introduced and sold in Europe.
Northeast Facility Manager, Jersey City, New Jersey, 1990-1992. Directed and managed the final facility design, construction, environmental impact resolution, distribution systems programming (including an automated storage and retrieval system) and facility start-up at Jersey City with a capacity of 80,000,000 cases. Project expenditure: $85,000,000.
SWEET VICTORY, INC., New York, New York, Vice President Manufacturing and Operations, 1987-1990. Full accountability for manufacturing and operations for start-up company of low calorie, low cholesterol frozen dairy desserts with three food service restaurants and a production facility in New York City.
HAAGEN DAZS COMPANY, INC. (Subsidiary of the Pillsbury Company), Teaneck, New Jersey, 1984-1987. Director, New Products Operations, 1985-1987. Full operational accountability for the process and equipment development, installations, start-up, manufacturing and distribution for the first Super Premium ice cream novelty product with resulting sales of over $150,000,000.
HAAGEN DAZS COMPANY, INC. (Subsidiary of the Pillsbury Company), Teaneck, New Jersey, Director, Operations, 1984-1985. Complete operational accountability for all manufacturing, distribution, procurement and quality of the companys products and subsidiarys operation (Sedutto Ice Cream).
THE PILLSBURY COMPANY, Minneapolis, Minnesota, 1977-1984. Director, Project Management Group and New Products Operations, 1982-1984. Programs and Projects worldwide budget of $67,000,000.
Director, Division Engineering Frozen Foods Group, Engineering responsibility for seven (7) manufacturing facilities, 14 engineering professionals, operating budget of $4,000,000, annual capital budgets of $21,000,000.
Senior Project Engineer Responsible for the site selection, design, construction and start-up of a frozen pizza manufacturing and distribution facility with an ASRS system.
GENERAL FOODS CORPORATION, Battle Creek, Michigan/Avon, New York, Senior Engineer.
CURTICE BURNS, INC., Rochester, New York, Engineering Designer
EDUCATION
UNIVERSITY OF ROCHESTER, Rochester, New York M.B.A., Operations Management
CORNELL UNIVERSITY, Ithaca, New York
B.S., Agriculture with Engineering and Technology, Food Science and Food Processing conc.
CERTIFICATIONS
Quality Auditor, Quality Manager: ASQ, 2000-2009
CPIM, CIRM, CSCP: APICS, 1996-2009
CARO, CIRO: RETA, 2003-2006
LICENSURE
Licensed Professional Engineer: Michigan, Minnesota, New York, New Jersey, Florida, 1982-2009
Licensed New Jersey 1A Gold Seal Steam Ops. / 2A Gold Seal Refrigeration
PROFESSIONAL DEVELOPMENT
Quality Systems, Professional Engineering and APICS - on-going professional development hours to maintain licenses and certifications
TPM ( Total Productive Maintenance) Training including AM, PM,FI, QA and HSE Pillar Training
SAP User & BW Training and Red Prairie Warehouse Management Super User Training
Diversity and Inclusion Training
AFFILIATIONS
National Society of Professional Engineers
Refrigeration Engineers & Technicians Association
American Society of Quality
APICS Association for Operations Management
International Institute of Ammonia Refrigeration
American Society of Agricultural and Biological Engineers, Various Committees related to Food Engineering, Safety and Standards
Institute of Food Technologists
Refrigerating Engineers & Technicians Association
|
