Brian Connolly

P/L responsibility for three business units at sites in Ohio and Nevada. Aligned division with TransDigm Group corporate value drivers, EBITDA requirements and on-time delivery performance targets. Drove improvement across all business units for profitability, product quality and preferred supplier status, manufacturing technology and regulatory compliance. Improved on-time delivery performance 15+%. Developed and implemented strategy resulting in 10% EBITDA improvement. Implemented state-of-the-art manufacturing automation and technology systems and developed customer-focused manufacturing strategy which reduced direct labor by 50%. Designed and built complex production work-centers in-house to replace aging systems, reducing cost of purchase by 40% and time to execute from 2.5 years to 1 year. Overhauled company ERP system which led to development of a deterministic production schedule, implemented sitewide project management system to eliminate redundant and unnecessary work, and implemented a Manufacturing Execution System to coordinate live data exchange between the ERP and plant floor work centers. Developed and implemented process safety and loss prevention risk analysis and audit system. Developed and implemented global supply chain stabilization and risk analysis system, including implementation of long-term supply agreements as appropriate, reducing raw material costs. Developed and implemented new R&D strategy to support cost reduction, existing product improvements, and new product and production technology development. Currently developing additional short-term strategies to reduce direct/indirect labor and improve EBITDA by 3-4%.

Led manufacturing technology innovation at three sites, including close daily manufacturing support, manufacturing process improvement and automated process controls. Developed and implemented 2 year, $10M batch and continuous automation strategy for extrusion and compounding production units at multiple sites using Rockwell Automation technology. Automated two extrusion lines and one compounding unit with associated material handling system. Developed automation and project template to complete additional extrusion lines and eliminate 30-40% of direct manufacturing headcount. Completed ROI in 2 years. Developed and trialed novel batch mixing system designed to shorten lead time and improve quality and yield. Developed and implemented new work instructions and operator training system. Developed and implemented process safety and loss prevention guidelines and audit system, including electrical safety processes such as Lock Out/Tag Out, Arc Flash, control panel Short Circuit Current Rating, and bonding/grounding. Developed Manufacturing 4.0 systems with advanced business intelligence and analytics data capture, storage and mining, corporate networking capability for all manufacturing sites, including real-time reporting for KPIs and order status. Includes real-time database connectivity between process control and business systems. Developed and implemented Quick Response Manufacturing model, while leveraging existing manufacturing, training, and engineering systems that utilize Lean/Six Sigma and Toyota Production System methodology.

P/L responsibility for three manufacturing plants in Ohio plus administration and HR responsibility for a petrochemical division in Texas.

Capital project development and management for specialty chemical manufacturing unit. Implemented $500K in capital and safety projects in 2 years and improved capacity by 20%. Developed unique production model responsible for commercialization of new product line, including unique process equipment and capital project for full-scale manufacturing. Pilot project was $75K with projected product annual sales of $1M. Process and project engineering for ceramic and plastic colorant divisions, specialty chemical manufacturing. Project engineering for $5M high pressure reactor project. Designed corporate automation strategy using Allen Bradley technology.

Process control and automation specialist. Automation project start-up specialist, I&E troubleshooting, process control template improvements, including process savings for extruder management reducing changeover time by 50%. Production unit supervision and engineering for chlor-alkali and polyethylene. Completed $500K in capital projects. Process engineering, capital project development and management. Process simulation using ASPEN, Knowledge Base Development using Level 5 Object. Process design for $10M chlor-alkali pilot plant.

Focus on polymer chemistry and engineering