LOUIS CARLUCCI
Buffalo,NY
Summary
Results-driven Lean Operations Manager with extensive experience leading manufacturing teams and driving operational excellence. Proven ability to improve productivity, reduce waste, and implement lean manufacturing principles to optimize performance. Skilled at developing high-performing teams, improving process efficiency, and fostering a culture of safety, accountability, and continuous improvement. 7 years in automotive leadership roles.
Value Stream Management professional with strong focus on team collaboration and achieving results. Proven track record in optimizing production processes, driving continuous improvement, and implementing lean methodologies. Adept at aligning cross-functional teams to streamline operations and enhance efficiency. Known for flexibility in adapting to changing needs and delivering impactful outcomes.
Overview
9
9
years of professional experience
Work History
Value Stream Manager
Silipos Holding
01.2025 - 01.2026
- Implemented OEE visual boards to track production rates and scrap
- Led and developed high-performing production, maintenance, and warehouse teams to improve operational efficiency and production reliability
- Increased production shipments by 200k each month and improved process reliability
- Developed standardized work and quality measures reducing scrap by 15% and improving OTD from 82% to 90%
- Improved workforce engagement and retention by addressing employee concerns and strengthening leadership communication, reducing turnover to 4%
- Implemented Gemba walks and 5S initiatives to engage associates in continuous improvement
- Coached and managed both maintenance and warehouse associates
- At a medical device with technologically advanced products.
Area Manager
Stryten Energy
01.2023 - 01.2025
- Responsible for the largest manufacturing department
- Directed 24/7 plastics manufacturing operations overseeing 65 associates, 4 supervisors, and 4 team leads to maintain production targets and operational performance
- Identified and drove opportunities for operational excellence and process efficiencies
- Ensured adherence to standardized work, quality audits and scrap reduction
- Trained and coached workforce using OEE and lean manufacturing principles
- Conducted regular Gemba walks to engage workforce on the floor level
- Plant department eliminated shifts and the position was no longer relevent.
Production Manager
Rosina Foods
02.2022 - 01.2023
- Responsible for plant production and sanitation on the night shift
- Managed 60 associates, 2 supervisors and 1 quality coordinator
- Ensured GMP compliance through coaching and training
- Developed cross-department relationships to maximize operational plans and plant revenue
- Reduced turnover by 20% through employee development and hiring improvements
Production Manager
Nutrablend Foods
06.2021 - 02.2022
- Responsible for operations and production targets
- Lead 100 associates and 3 supervisors in a 24/5 operation
- Increased production by 15% and reduced scrap by 20%
- Reduced absenteeism by 30% by enforcing HR policies
- Reduced turnover by improving hiring and reducing the temp workforce from 30% to 10%
- Implemented KPI dashboards, TPM and Pareto charts to reduce downtime and increase throughput
- Plant was sold to canadian investors and the leadership team was laid off
Continuous Improvement Leader
Thermo Fisher Scientific
01.2020 - 05.2021
- Responsible for Lean initiatives and Six Sigma projects
- Led processing teams to improve product quality and exceed production KPIs
- Strong understanding of inventory management principles and systems
- Proven ability to analyze data and drive process improvements
- Ensure consistent and repeatable assembly processes to maintain product quality
- Drive continuous improvement in production flow and standard work
- Experience working in a cleanroom or controlled environment
- Lead, coach, and hold technicians accountable for performance, quality, and process adherence
- Ensure adherence to defined processes, procedures, and documentation requirements
- Experience in a clean room aseptic processing and packaging
Manufacturing Supervisor
Cascades Paper
04.2017 - 01.2020
- Responsible for the manufacturing process of a paper mill
- Led continuous improvement initiatives to reduce plant scrap
- Managed a $250k Kaizen project increasing production rates by 30%
- Implemented safety observation tours resulting in 800 days with zero OSHA recordables
- Fostered collaborative work environment improving productivity and morale
- Coordinated joint health and safety meeting with the union leadership
- Supervised daily manufacturing operations, ensuring adherence to safety and quality standards.
Education
Bachelor of Science - Business Management
Buffalo State University
Buffalo, NY05.1991
MBA - Business
Canisius University
Buffalo NY05.2027
Skills
- Lean Manufacturing
- Process Improvement
- Continuous improvement
- OEE Optimization
- Six Sigma / Kaizen
- Standardized Work
- KPI & Performance Metrics
- Operational Excellence
- Team Leadership & Development
- Safety & Compliance
- 5S Methodology
- Root Cause Analysis
- ISO Environment Experience
- Coaching and Developing
- Microsoft word, excel, power point
Timeline
Value Stream Manager
Silipos Holding
01.2025 - 01.2026
Area Manager
Stryten Energy
01.2023 - 01.2025
Production Manager
Rosina Foods
02.2022 - 01.2023
Production Manager
Nutrablend Foods
06.2021 - 02.2022
Continuous Improvement Leader
Thermo Fisher Scientific
01.2020 - 05.2021
Manufacturing Supervisor
Cascades Paper
04.2017 - 01.2020
Bachelor of Science - Business Management
Buffalo State University
MBA - Business
Canisius University