Joseph D. Cairo
Cranston
Summary
Dynamic and forward-thinking management professional with a proven record of advancement through roles of increasing responsibility in the manufacturing industry. Over thirty years of experience leading operational transformations, scaling teams, and driving continuous improvement in both domestic and international settings. Recognized for strategic vision, adaptability, and expertise in cross-cultural leadership, consistently delivering measurable business results including multimillion-dollar cost reductions, productivity enhancements, and world-class safety performance. Adept at building and motivating high-performing teams, leveraging data-driven decision-making, and implementing lean methodologies to exceed organizational objectives. Exceptional communicator, collaborator, and change agent capable of aligning diverse stakeholders toward shared goals.
Overview
31
31
years of professional experience
Work History
Head of Operations
Igus, Inc
09.2022 - 09.2025
- Directed the design and launch of a highly automated, 100,000 sq. ft. injection molding facility, increasing production capacity by 75% and reducing operational costs by 25% within the first year.
- Currently leading operations for molding, engineering, planning, inventory, and distribution, managing a team of 20+ employees and delivering 99% on-time order fulfillment.
- Maintained a perfect safety record with zero lost-time accidents throughout construction and ongoing operations.
- Developed optimized factory layouts, resulting in a 50% improvement in material flow and a 10% reduction in cycle times.
- Oversaw contractor management and equipment procurement, completing projects under budget and ahead of schedule by 3 months.
- Collaborated with HR to recruit, and onboard 20+ new staff while driving a 50% increase in workforce capabilities through Lean Improvements.
- Implemented lean workflow strategies across all production areas, achieving a 25% reduction in waste and a 30% increase in throughput.
- Directed the global transfer of 500 tools from headquarters in Europe.
- Consistently met or exceeded financial and operational targets for capital expenditures and start-up activities.
- Served as ERP superuser, leading North American transition to advanced ERP systems and improving inventory accuracy to 99.5%.
- Currently spearheading design and planning for a new 120,000 sq. ft. machining and assembly facility, projected to increase output by 50% and support future growth initiatives.
- Career Progression: Head of Operations with expanded oversight of major facility projects and cross-functional teams.
Operations and Project Manager, WCM Site Leader
Saint-Gobain Performance Plastics
01.2003 - 09.2022
- Led the transition of the Aerospace Business from Ohio to Bristol, RI, relocating 80% of a $20M annual sales operation and integrating 40 machines and 70 new employees in under six months.
- Supervised up to 80 direct reports and managed 150+ indirect reports across operations, supply chain, quality, and engineering, growing site workforce by 85% over tenure.
- Served as World Class Manufacturing (WCM) Site Manager, delivering $1.5M+ in annual savings through loss deployment and policy deployment initiatives.
- Developed and trained multi-skilled teams, increasing cross-departmental flexibility and productivity by 20%.
- Oversaw facilities, project, and capital expenditure management, successfully completing 10+ major projects with a combined budget of $12M.
- Superuser in MRP and ERP systems (Infor, QAD, MES), improving production scheduling accuracy to 98% and reducing stockouts by 70%.
- Directed global manufacturing relocations and start-ups in Germany, Mexico, and China, resulting in a 30% increase in international output and streamlined equipment integration.
- Maintained zero lost-time accidents for over sixteen years, establishing a culture of safety and accountability.
- Achieved twelve consecutive years of inventory accuracy (variance
- Applied lean and WCM techniques to eliminate bottlenecks and reduce direct labor costs by 25% while increasing process throughput.
- Ensured compliance with ISO9001, AS9100, IATF16949, and ISO14001 certifications, supporting customer and regulatory requirements.
- Advancement: Progressed from project manager to site leader, expanding responsibility for global operations and team management.
Injection Molding Team Lead/Supervisor
Uvex Safety Inc
09.1994 - 01.2003
- Managed all technical aspects of a 70-machine injection molding department, increasing throughput by 25% through process optimization and automation.
- Supervised and trained a team of 25 employees, reducing turnover by 35% and enhancing skillsets through targeted development.
- Established and maintained optimal processing conditions, resulting in a 15% reduction in scrap rates and improved product quality.
- Led the installation and programming of new molding machines, tooling, and robotics, supporting a 20% expansion in production capability.
- Growth: Advanced from technician to department supervisor, overseeing technical operations and team development.
Education
High School Diploma -
Johnston High School
01.1993
BS Degree - Business Management
Roger Williams University
01.2010
Supervisory/Management Training - undefined
University of New Hampshire
01.2004
Management Development Institute (MDI) - undefined
Saint-Gobain
01.2010
Six Sigma Green Belt Certification - undefined
BMGI
01.2006
World Class Manufacturing Lean Green Belt - Industrial Efficiency
Efeso
01.2015
Skills
- Strategic Operations Leadership: Advanced from team leader to head of operations, consistently expanding scope and driving facility-wide improvements
- Employee Safety & Engagement: Achieved zero lost-time accidents over multiple years; championed safety-first culture and employee well-being
- Project & Facility Management: Led multi-million-dollar site expansions, relocations, and start-ups across North America, Europe, and Asia
- Lean Manufacturing & Continuous Improvement: Six Sigma and Lean Greenbelt Certified; delivered annual savings exceeding $15M through process optimization
- Cross-Cultural Leadership & Adaptability: Directed global teams and projects, successfully navigating diverse business environments
- Team Development & Training: Built and scaled teams by 75 members; developed cross-functional, multi-skilled workforces
- ERP/MRP Implementation: Superuser in planning, inventory, and supply management; led seamless ERP transitions
- P&L and Capital Expense Management: Owned and met financial targets for capital projects, driving operational profitability
- Stakeholder Collaboration: Effectively partnered with management, finance, HR, IT, engineering, and supply chain
Timeline
Head of Operations
Igus, Inc
09.2022 - 09.2025
Operations and Project Manager, WCM Site Leader
Saint-Gobain Performance Plastics
01.2003 - 09.2022
Injection Molding Team Lead/Supervisor
Uvex Safety Inc
09.1994 - 01.2003
BS Degree - Business Management
Roger Williams University
Supervisory/Management Training - undefined
University of New Hampshire
Management Development Institute (MDI) - undefined
Saint-Gobain
Six Sigma Green Belt Certification - undefined
BMGI
High School Diploma -
Johnston High School
World Class Manufacturing Lean Green Belt - Industrial Efficiency
Efeso