Albert Cappucci
Macungie,PA
Summary
Senior Plant Manager with 25+ years of experience driving transformational and operational excellence in diverse industries. Skilled at revitalizing operations through teamwork, accountability, and effective communication. Strategic leader overseeing multiple sites and shifts in fast - paced production environments. Motivational change agent breaking records and exceeding KPI’s. Holds an MS in Business Administration and certifications as a Black Belt Lean Six Sigma, ISO 9001:2015, and Life Cycle Engineering.
Overview
14
14
years of professional experience
1
1
Certification
Work History
Senior Director of Operations
Sechan Electronics Inc.
Lititz, PA
02.2024 - Current
- Transformed operations in struggling electronics company with $210M annual revenue.
- Implemented cross-training programs and tracked metrics to enhance workforce efficiency.
- Facilitated meetings among department managers to align organizational goals.
- Recalibrated work order standards to ensure accurate tracking of efficiencies.
- Improved capacity planning accuracy to optimize workload versus headcount.
- Established second shift, increasing daily output and enhancing on-time deliveries.
- Developed monthly prioritization system for effective workload management.
Plant Manager / General Manager
Reeb Millwork, Specialty Building Products Corporation
Bethlehem, PA
08.2021 - 06.2023
- Company Overview: Tasked with revitalizing and revamping the operations of an 800,000 sqft facility assembling interior and exterior doors with an annual revenue of $250M.
- Oversaw Production, Warehouse, Shipping, Receiving, Maintenance, Logistics, Fleet Maintenance, Quality Control and Safety.
- Implemented cross training, tracking metrics, visual boards, Six Sigma, 6S, TPM, and TQM methodologies.
- Improved facility ranking from #3 out of five to #1.
- Reduced a 5-day 48-hour work week to a 4-day 40-hour work schedule.
- Introduced a damaged door recovery program, saving $1.2M.
- Increased avg daily units produced from 1,400 to 1,850.
- Slashed OT by 65%, saving $690,000.
- Tasked with revitalizing and revamping the operations of an 800,000 sqft facility assembling interior and exterior doors with an annual revenue of $250M.
Plant Manager
Trouw Nutrition, Nutreco Corporation
Strykersville, NY
05.2019 - 07.2021
- Company Overview: Challenged as a change agent to turnaround 2-shift dairy feed mill operation with $55M annual revenue. Producing both medicated and non-medicated feed; HACCP, PCQI certified.
- Responsible for Maintenance, Safety, Quality, Logistics and Production teams.
- Implemented cross training, tracking metrics, visual boards, Six Sigma, 6S, TPM, and TQM methodologies.
- Reduced OT saving $374,000.
- Implemented 2nd Shift Mechanics to increase PM completions from 65% to 100%.
- Increased truck load capacity from 61% to 89%.
- Enhanced on-time delivery performance from 97% to 100%.
- Challenged as a change agent to turnaround 2-shift dairy feed mill operation with $55M annual revenue. Producing both medicated and non-medicated feed; HACCP, PCQI certified.
General Manager / Plant Manager
Schutt Reconditioning
Easton, PA
05.2017 - 03.2019
- Company Overview: Hired to revamp operations and to create a Lean environment for one of the largest sports helmet reconditioning and manufacturing company.
- Responsible for multiple sites, on time shipping, cost per unit, labor forecasting, customer satisfaction, reduction of inventory and ensuring that HR policies were followed.
- Implemented cross training, tracking metrics, visual boards, Six Sigma, 6S, TPM, and TQM methodologies.
- Created quality codes for tracking root cause analysis.
- Implemented a scannable barcoding system.
- Increased helmet heater capacity 200%, redesigning the heater and helmet racks.
- Developed a hardware reclaiming process resulting in $425,000 in savings.
- Improved on-time deliveries from 83% to 98%.
- Hired to revamp operations and to create a Lean environment for one of the largest sports helmet reconditioning and manufacturing company.
Director of Operations
JSB Windkits LLC
Allentown, PA
06.2016 - 05.2017
- Company Overview: Directed the operations for a balsa and foam kit supplier for the wind turbine industry with $41M annual revenue.
- Implemented cross training, tracking metrics, visual boards, Six Sigma, 6S, TPM, and TQM methodologies.
- Oversaw employee development, training, plant scheduling, interviewing, customer contact, root cause analysis, financial tracking, safety implementation, supplier evaluation, and process improvement.
- Boosted productivity from 65% to 100%.
- Reduced OT from 26% to 1%.
- Increased on-time deliveries from 58% to 98%.
- Minimized equipment downtime from 26% to 1% by implementing operator PM checklists.
- Directed the operations for a balsa and foam kit supplier for the wind turbine industry with $41M annual revenue.
Direct Operations / Site Manufacturing Leader
PsPrint, A Deluxe Corporation
Bethlehem, PA
12.2013 - 01.2015
- Company Overview: Managed a three-shift web - print manufacturing operation with $10.9M in annual revenue.
- Implemented cross training, tracking metrics, visual boards, Six Sigma, 6S, TPM, and TQM methodologies.
- Increased the facility ranking from #4 out of four to #1.
- Reduced OT by 65% through cross-training initiatives.
- Enhanced productivity from 81% to 100%.
- Raised on-time deliveries from 83% to 99.8%.
- Reduced paper waste 34%.
- Managed a three-shift web - print manufacturing operation with $10.9M in annual revenue.
Director of Operations & Logistics
Burbee Seed Company
Warminster, PA
09.2011 - 01.2013
- Company Overview: Hired as a change agent to develop an organizational strategy to increase communications, leadership development, create SOP’s, and implement Lean Six Sigma methodologies.
- A 3-shift multi-site seed and seed starter kit production and manufacturing operation.
- Implemented cross training, tracking metrics, visual boards, Six Sigma, 6S, TPM, and TQM methodologies.
- Transformed operations from 1 shift to 3 shifts.
- Increased on-time deliveries from 68% to 98.3%.
- Slashed inventory by 40%, removing 150 old sku’s.
- Expanded warehouse racking by 40%, through the installation of wire-guided narrow aisle racking.
- Increased intermodal shipping from 15% to 60%.
- Hired as a change agent to develop an organizational strategy to increase communications, leadership development, create SOP’s, and implement Lean Six Sigma methodologies.
Education
MS - Business Administration
Kennedy Western University
BS - Management of Technology
Kennedy Western University
A & P Mechanics License -
Teterboro School of Aeronautics
Skills
- Leadership and team building
- Plant management and operations
- Employee safety and compliance
- Mentoring and development
- Customer satisfaction and engagement
- Lean Six Sigma methodologies
- Total productive maintenance (TPM)
- Total quality management (TQM)
- 5S and 6S practices
- Gemba walks and observations
- Budget planning and P&L management
- Cost reduction strategies
- Continuous process improvement initiatives
- Change management agent
- OSHA, DOT, EPA, and FDA compliance
Certification
- Black Belt Lean Six Sigma, Acuity Business Institute.
- Life Cycle Engineering, Clemson University.
- Kaizen Facilitator, Acuity Business Institute.
- Quality Management System ISO 9001:2015, Manufacturers Resource Center.
- Hazard Analysis Critical Control Point (HACCP) Plan Development, Registrar Corp.
- Preventive Controls Qualified Individual (PCQI), Food Safety Preventive Controls Alliance (FSPCA).
- FAA Airframe Mechanics License, Teterboro School of Aeronautics.
- FAA Powerplant Mechanics License, Teterboro School of Aeronautics.
Reason For Job Changes
- 2021 – 2023 Reeb Millwork Vice President lost two facilities out of five assumed my role.
- 2019 – 2021 Trouw Nutrition the company was sold I was offered a Global Assessment Leadership position in the Netherlands.
- 2017 – 2019 Schutt Reconditioning led the transition team moving operations to Mexico.
- 2016 – 2017 JSB Windkits The company moved to Mexico.
- 2013 – 2015 PsPrint company relocated out of state. Offered the National Director position.
- 2011 – 2013 Burpee Seed Company director positions were eliminated.
Timeline
Senior Director of Operations
Sechan Electronics Inc.
02.2024 - Current
Plant Manager / General Manager
Reeb Millwork, Specialty Building Products Corporation
08.2021 - 06.2023
Plant Manager
Trouw Nutrition, Nutreco Corporation
05.2019 - 07.2021
General Manager / Plant Manager
Schutt Reconditioning
05.2017 - 03.2019
Director of Operations
JSB Windkits LLC
06.2016 - 05.2017
Direct Operations / Site Manufacturing Leader
PsPrint, A Deluxe Corporation
12.2013 - 01.2015
Director of Operations & Logistics
Burbee Seed Company
09.2011 - 01.2013
MS - Business Administration
Kennedy Western University
BS - Management of Technology
Kennedy Western University
A & P Mechanics License -
Teterboro School of Aeronautics
Similar Profiles
Angie LefeverAngie Lefever
Associate Quality Engineer at Sechan ElectronicsAssociate Quality Engineer at Sechan Electronics
Caroline Le AnnaCaroline Le Anna
Final Assembler at Sechan ElectronicsFinal Assembler at Sechan Electronics
Shivam BavankarShivam Bavankar
NA at Self Employed - Electronics & Digital Goods Retailer Royal ElectronicsNA at Self Employed - Electronics & Digital Goods Retailer Royal Electronics
Dylan DarvilleDylan Darville
Data Analyst at Waigr IncData Analyst at Waigr Inc
Gregory J. GriffithGregory J. Griffith
Field Service Engineer (Mid-Atlantic) at Intuitive SurgicalField Service Engineer (Mid-Atlantic) at Intuitive Surgical