MARCELLO A. FALVO
Venice,FL
Summary
Operations and Maintenance Leader with over 30 years of experience managing manufacturing facilities, maintenance operations, capital projects, process improvements, budgets, contractors, and cross-functional teams within chemical, cosmetic, consumer products, packaging, and manufacturing environments. Proven success leading capital equipment installations, improving equipment reliability, reducing downtime, strengthening preventive maintenance programs, lowering contractor costs, and supporting production line startups. Experienced managing maintenance and facilities budgets of up to $700K, coordinating capital projects totaling up to $4 million, implementing OSHA- and GMP-compliant procedures, and driving Lean, 5S, and Gemba-based continuous improvement initiatives. Recognized for building collaborative relationships across organizations, developing high-performing teams, and delivering sustainable operational and financial results.
Overview
32
32
years of professional experience
Work History
Maintenance & Facilities Manager
Pflaumer Brothers Inc.
01.2022 - Current
- Lead maintenance and facilities operations supporting chemical manufacturing and distribution activities.
- Managed annual maintenance and facilities budgets of approximately $600K, ensuring effective capital planning and resource allocation for maintenance operations and facility improvements.
- Led capital projects totaling approximately $175K, including installation and commissioning of reactors, mixing vessels, storage tanks, pumps, HVAC systems, air compressors, and nitrogen supply systems.
- Oversaw capital project execution from planning through installation, commissioning, and startup, ensuring seamless turnover to operations.
- Develop and implement preventive maintenance programs, maintenance schedules, inspection procedures, and asset management processes to improve equipment reliability.
- Improved preventive maintenance completion rates by approximately 75% through stronger scheduling, documentation, inspection routines, and technician accountability.
- Reduced equipment downtime by approximately 20% through improved troubleshooting practices, preventive maintenance planning, and root cause analysis.
- Analyzed maintenance and operational performance data to identify trends and inform strategic decisions that reduced downtime.
- Create SOPs, GMPs, maintenance documentation, and compliance programs supporting OSHA requirements and operational excellence initiatives.
- Manage external contractors, vendors, and service providers to ensure project completion, cost control, safety compliance, and quality outcomes.
- Reduced contractor/vendor costs by approximately $100K by bringing selected maintenance activities in-house, improving work planning, and strengthening vendor oversight.
- Partner with senior leadership to improve workplace safety, operational efficiency, and long-term equipment reliability.
- Mentor engineering and maintenance personnel, supporting knowledge transfer, employee development, and improved team performance.
Packaging Engineer / Project Lead
Keystone Industries
01.2020 - 01.2022
- Led packaging, filling, and manufacturing equipment upgrade projects to improve efficiency, throughput, and production performance.
- Managed equipment installations and workflow optimization initiatives and enhancing operational efficiency across manufacturing operations.
- Improved line efficiency by approximately 15% through equipment troubleshooting, process adjustments, workflow improvements, and cross-functional collaboration.
- Identified and resolved packaging and filling equipment issues to improve uptime, product flow, and overall line performance.
- Supported the successful startup of 2 production lines, including equipment setup, process validation support, troubleshooting, training, and operational handoff.
- Reduced production interruptions by approximately 20% through improved changeover support, troubleshooting, and equipment reliability improvements.
- Collaborated with operations, engineering, maintenance, and quality teams to improve productivity and reduce operational bottlenecks.
- Utilized operational data and performance metrics to pinpoint opportunities for equipment and process enhancements.
- Updated SOPs and training materials, ensuring standardized operations and fostering consistent production practices.
- Supported continuous improvement initiatives focused on safety, efficiency, equipment reliability, and operational effectiveness.
Senior Facilities & Maintenance Engineer
Northtec, LLC, Formerly Estee Lauder
01.2001 - 01.2020
- Managed maintenance activities to ensure seamless operations in manufacturing, compounding, packaging, and facility functions.
- Managed maintenance resources, project priorities, contractors, and capital initiatives supporting high-volume manufacturing operations.
- Supported annual maintenance and facility budgets of approximately $700K, assisting with cost control, project prioritization, contractor management, and operational planning.
- Led capital improvement projects totaling approximately $4 million, including equipment installations, facility modifications, production support systems, and process improvements.
- Led vendor and contractor relationships for facility upgrades, construction projects, equipment installations, and major repair initiatives.
- Directed capital projects from planning through execution, ensuring alignment with operational goals, budget requirements, safety standards, and business priorities.
- Played a key role in developing and implementing GMP-compliant procedures, maintenance standards, and operational best practices.
- Partnered with leadership teams to streamline operations using Lean Manufacturing, Gemba, and 5S methodologies.
- Led development and implementation of an in-house CNC machine shop from concept through full operational deployment.
- Reduced reliance on outside machining vendors by approximately $250K annually by establishing internal machining capabilities and improving turnaround time.
- Improved equipment reliability and reduced downtime by approximately 20% through preventive maintenance planning, troubleshooting, root cause analysis, and cross-functional maintenance support.
- Improved preventive maintenance performance by approximately 30% through enhanced scheduling, documentation, technician training, and maintenance planning.
- Provided technical leadership for process improvements, equipment reliability initiatives, and manufacturing support programs.
- Developed and delivered training programs for engineers, maintenance personnel, and new employees.
- Fostered a culture of continuous improvement and operational excellence, enhancing collaboration and safety across the organization.
Engineer Level I
Northtec, LLC, Formerly Estee Lauder
01.1998 - 01.2001
- Developed preventive maintenance strategies and operational improvements to increase equipment performance and reliability.
- Assisted with equipment reliability improvements that contributed to reduced downtime and stronger maintenance performance.
- Supported manufacturing and facilities operations by troubleshooting equipment, improving processes, and planning maintenance activities to enhance operational efficiency.
- Collaborated with leadership on facility and equipment enhancement projects.
- Assisted with maintenance documentation and drove equipment reliability improvements to support operational activities.
Engineer Trainee
Northtec, LLC, Formerly Estee Lauder
01.1996 - 01.1998
- Contributed to maintenance and reliability initiatives, ensuring optimal operations in manufacturing and facilities.
- Collaborated with senior engineers and maintenance personnel on troubleshooting and documentation to drive continuous improvement.
- Assisted with equipment repairs and upgrades, enhancing operational reliability and supporting process improvements.
- Developed foundational expertise in manufacturing equipment, maintenance systems, facility systems, and operational processes.
Compounder
Northtec, LLC, Formerly Estee Lauder
01.1995 - 01.1996
- Produced cosmetic powder products, ensuring consistent quality through effective use of industrial mixing, milling, and manufacturing equipment.
- Acquired in-depth understanding of powder processing systems and optimized manufacturing operations and production workflows.
- Executed production procedures and adhered to safety requirements and quality standards in the GMP manufacturing environment, contributing to overall compliance and product integrity.
Education
Computer Integrated Manufacturing, CIM
Camden County College
01-2012
General Studies
Mercer County College
01-1998
Notre Dame High School
Lawrenceville, NJ01-1987
Skills
- Operations Leadership
- Facilities Management
- Maintenance Management
- Capital Project Coordination
- Project Management
- Process Improvement
- Lean Manufacturing, 5S & Gemba
- Preventive & Predictive Maintenance
- SOP & GMP Development
- OSHA Compliance
- Vendor & Contractor Management
- Budget Planning & Cost Control
- Equipment Reliability
- Root Cause Analysis
- Employee Training & Development
- Change Management
- Production Line Startup Support
- Contractor Cost Reduction
- Maintenance Planning & Scheduling
- Microsoft Excel
- Microsoft Word
- Microsoft PowerPoint
- SAP
- Maximo
- MP2
- CMMS Systems
- AutoCAD
- Mastercam
- Technical Documentation & Reporting
- Data Analysis & Reporting
ADDITIONAL QUALIFICATIONS
- Extensive experience supporting chemical, cosmetic, packaging, compounding, and manufacturing operations.
- Proven ability to lead cross-functional projects, capital improvements, equipment installations, and operational improvement initiatives.
- Strong communication, organizational, leadership, and problem-solving skills.
- Experienced presenting recommendations, project updates, cost information, and operational performance data to senior leadership.
- Demonstrated success developing teams, improving processes, reducing downtime, and driving operational excellence.
- Strong background in GMP environments, OSHA compliance, vendor management, preventive maintenance, contractor oversight, and capital project execution. Experienced supporting production line startups, equipment commissioning, maintenance planning, and process standardization
Timeline
Maintenance & Facilities Manager
Pflaumer Brothers Inc.
01.2022 - Current
Packaging Engineer / Project Lead
Keystone Industries
01.2020 - 01.2022
Senior Facilities & Maintenance Engineer
Northtec, LLC, Formerly Estee Lauder
01.2001 - 01.2020
Engineer Level I
Northtec, LLC, Formerly Estee Lauder
01.1998 - 01.2001
Engineer Trainee
Northtec, LLC, Formerly Estee Lauder
01.1996 - 01.1998
Compounder
Northtec, LLC, Formerly Estee Lauder
01.1995 - 01.1996
Computer Integrated Manufacturing, CIM
Camden County College
General Studies
Mercer County College
Notre Dame High School