MARC POWELL
Anderson,SC
Summary
Highly accomplished hands on manufacturing and warehousing management professional with 25 plus years of experience in operations, performance management, team management, safety and regulatory compliance, financial management and strategic planning. Results-oriented, decisive leader with proven success in implementing and maintaining effective process improvements. Proficient in planning, coordinating and executing successful production strategies. Adept at improving operational stability, efficiency and profitability.
Overview
28
28
years of professional experience
Work History
East Coast Operations Manager-Consulting Contract
Royal Gold, LLC
McKinleyville, CA
04.2021 - 08.2022
- Partnered with ownership and senior management to develop and implement East Coast expansion plans utilizing either contract manufacturing, new company owned manufacturing facility or combination of both to support sales and profitability objectives. Closed on new company owned facility June 2022
- Successfully sourced and provided detailed analysis of various leased warehousing facilities and purchased property opportunities for warehousing or manufacturing facility.
- Created operating and capital budgets for year 1 startup operations and then 3 year plans for ongoing operations with emphasis on under and fully absorbed forecasting.
- Developed breakeven analysis for various sales and costing scenarios for improved decisions on sales price, raw material purchasing/usage and staffing.
- Successfully sourced contract manufacturers for existing formulations and new products to support new East Coast markets
- Coordinated with R&D and Sale & Marketing teams to develop new product formulations for Greenhouse Grower markets and Independent Garden Centers to expand business into additional markets.
- Successfully sourced new raw materials, vendors and contract manufacturers to support sales and profitability objectives of current and new formulations to support business expansion into new markets.
- Led team in sourcing and purchasing manufacturing and packaging equipment along with two ClearSpan Fabric structure buildings.
Distribution Manager
Hawthorne Hydroponics LLC, Scotts Miracle Gro, Wixom MI
York, PA
11.2019 - 02.2021
- Implemented strategic plans as well as contributed to evaluation and analysis of business objectives.
- Managed 100,000 sq ft facility in providing proper inventory, order fulfillment and receiving activities to support sales growth of $25mm in 2020.
- Coached and managed 6 direct reports and 100 indirect reports by end of 2020.
- Improved operational efficiency by recruiting and developing top talent to drive growth initiatives. Staffing increased from 40 to 85 associates within 6 month timeframe.
- Worked closely with supervisors and staff to successfully reduced order lead time from 2 weeks to 24 hours.
- Managed change and growth of business - added weekend shift for increased output, moved all inbound activities to 3rd shift for increased efficiency , added 3PL for increased inventory capacity, moved operations from 100K sq. ft. facility to 250k sq. ft. facility to meet company's growth objectives, all within 12 month period.
- Guided DC operations from onset of Covid-19 through ever changing guidance and protocols from local, state, federal Governments and Corporate EHS.
Plant Manager
Hawthorne Hydroponics LLC, Scotts Miracle Gro
Martinsburg, WV
05.2017 - 11.2019
- Successfully managed plant operations to support liquid nutrient production increases of 40% for 2019
- Led successful startup and then full production of both Botanicare and Commercial liquid nutrient products to support East Coast and Canadian sales activities
- Partnered with finance to develop KPI's to measure and track production improvement performance, develop operating and capital budgets, as well as, other financial tools to manage the business
- Drove plant level integration activities for EHS, HR, Finance, Supply Chain, Customer Service, along with implementing Hawthorne policies and procedures
- Managed labor costs down $200k to match needs of business in 2018
- Financial responsibilities include cost center accountability, cost absorption, operating and capital budgeting, as well, year-end physical inventories.
Director East Coast Operations
FOX FARM SOIL & FERTILIZER COMPANY
Samoa, CA
06.2013 - 01.2016
- Led acquisition team and successful start-up of new $4.5MM growing media manufacturing facility to include evaluating pros/cons of various sites, final site selection, managing purchasing process with seller, attorneys, environmental and other local agencies, along with $1.5MM incentive package through county development board. Closed July 2014
- Directed team in sourcing and purchasing manufacturing/packaging equipment, repurposing 150,000 sq ft of warehouse space for equipment installations, finished goods and raw materials storage areas
- Managed successful installation of manufacturing/packaging equipment, in addition to all electrical, mechanical and pneumatic requirements for both current and future expansion of manufacturing facility
- Led team in successfully calibrating mix line equipment for raw materials to product formulations and quality specifications to within 2% variance
- Guided hiring and training of management and production staffs, then successfully managed production and administration startups
- Coached and directly managed 3 direct reports and 18 indirect reports. Successful plant start-up in March 2015
- Led management team in implementing company policy and procedures, adjusted where necessary, for safety, quality control, production, maintenance and administrative areas
- Successfully managed facility to support 60% sales increase during first 9 months of operations
- Created annual operational budgets, three year capital forecasts, annual cash flow forecasts, successfully managed quarterly and year-end inventory audits
- Directed successful sourcing of raw materials, established and managed vendor relationships
- Successfully managed closure of distribution center in Pageland SC and relocation of all company assets and inventory to new facility.
General Manager
South Carolina, SUN GRO HORTICULTURE, ACQUIRED CONRAD FAFARD, INC
Agawam, MA
06.2012 - 05.2013
- Directed two growing media manufacturing and bark processing facilities to support sales of $28MM and managed operational budgets of $6MM
- Coached and directly managed 5 direct reports and 75 indirect reports
- Implemented coaching and training programs to develop staff, facilitate efficiency, improve performance and skill sets of all employees
- Continually evaluated operational activities and implemented process improvements to ensure superior quality and consistent products
- Identified, drove and supported change management activities for all employees to ensure continuous improvement
- Financial responsibilities include P&L accountability, operating and capital budgeting - both short and long term, quarterly and year-end inventory audits
- Oversaw forecasting and procurement of raw materials, vendor relationships, production output and inventory builds to seasonal demands
- Managed plant level integration activities for HS&E, ERP, product formulations, SKU consolidations, raw material uniformity, geographic alignment of manufacturing and reporting responsibilities, along with implementation of Sun Gro policies and procedures
- Led team to develop and implement operational, equipment and capital plans to relocate bulk growing media manufacturing and bark processing facility from McCormick SC to Anderson SC. Capital outlay of $2.5MM
Director US Manufacturing Operations
CONRAD FAFARD, INC
Agawam, MA
04.2008 - 06.2012
- Directed three growing media manufacturing/bark processing facilities and one retail peat plant to support sales of $40MM and managed operational budgets of $9MM
- Directly managed 7 direct reports and 100 indirect reports
- Financial responsibilities include P&L accountability, operating and capital budgeting - both short and long term, managing seasonal inventory levels, quarterly and year-end audits
- Led integration of manufacturing operations to Syngenta management style - HS&E, performance management, skill set development, SOX compliance and standard costing conversion resulting in positive culture change, improved efficiency, pride in ownership of jobs/workplace and transparent work environment
- Coached 4 plant managers and 9 supervisors on financial objectives, developing and improving skill sets for all employees, empowering all employees to make decisions and creating open communication across all operations
- Reduced recordable injuries 60% in 2010 and additional 50% in 2011
- Led manufacturing team on product development of two new SKU's for Lowe's, including raw material sourcing, new equipment purchases, forecasting and inventory builds to support successful product launch in obtaining sales objectives.
Operations Manager
CONRAD FAFARD, INC
Agawam, MA
07.1996 - 04.2008
- Managed all HS&E, manufacturing, maintenance, human resource and bark processing activities of two growing media manufacturing facilities, with a third manufacturing facility added in 2007
- Directly managed 6 direct reports and 75 indirect reports
- Financial responsibilities include P&L accountability, operating and capital budgeting - both short and long term, quarterly and year-end inventory audits
- Managed forecasting and procurement of raw materials, production output and inventory builds to seasonal demands
- Managed production scheduling, staffing requirements/development, short and long term operational planning, equipment improvements and plant expansion, as well as, lean manufacturing initiatives for continuous improvement
- Managed manufacturing outputs to support sales growth of over 400% over ten year period
- Plant level Fafard lead on Syngenta integration projects relating to HS&E, HR, SOX compliance, new ERP platform and standard costing conversion for all products.
- Implemented process improvement to shape organizational culture, optimize procedures for higher efficiency and help company evolve and grow
Project Manager (contract Employee 11/92-11/93)
CONRAD FAFARD, INC
Agawam, MA
11.1992 - 07.1996
- Managed construction, land development and startup of new growing media manufacturing and bark processing facility with total capital outlay of $3MM. Project completed on schedule.
- Oversaw selection, purchase, installation, calibrations and startup of manufacturing equipment - mix line, packaging and bark processing equipment
- Created SOPs for all new equipment to facilitate safe operating procedures and training for associates
- Managed additional capital expansion projects at both South Carolina and Florida facilities for equipment and land development
- Developed and implemented production forecast for manufacturing of inventories and raw material procurement
- Identified and implemented process improvements to increase production output and efficiency, while minimizing or reducing labor costs.
Education
No Degree -
Skills
- Strategic thinker/planner
- Team building & training
- P&L accountability
- HS&E
- Analytical skills
- Change Management
- Leadership and training
- Problem solving
- Continuous improvement
- Budgeting and forecasting
Affiliations
Mulch and Soil Council Board of Directors
Timeline
East Coast Operations Manager-Consulting Contract
Royal Gold, LLC
04.2021 - 08.2022
Distribution Manager
Hawthorne Hydroponics LLC, Scotts Miracle Gro, Wixom MI
11.2019 - 02.2021
Plant Manager
Hawthorne Hydroponics LLC, Scotts Miracle Gro
05.2017 - 11.2019
Director East Coast Operations
FOX FARM SOIL & FERTILIZER COMPANY
06.2013 - 01.2016
General Manager
South Carolina, SUN GRO HORTICULTURE, ACQUIRED CONRAD FAFARD, INC
06.2012 - 05.2013
Director US Manufacturing Operations
CONRAD FAFARD, INC
04.2008 - 06.2012
Operations Manager
CONRAD FAFARD, INC
07.1996 - 04.2008
Project Manager (contract Employee 11/92-11/93)
CONRAD FAFARD, INC
11.1992 - 07.1996
No Degree -
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