Thomas Mulligan
Weehawken
Summary
Dynamic leader with a proven track record at Sanofi, excelling in manufacturing execution and contamination control. Spearheaded the implementation of lean principles, driving a culture of continuous improvement. Renowned for enhancing performance management and problem-solving capabilities, resulting in significant operational efficiencies and a robust vaccine supply chain.
Overview
24
24
years of professional experience
1
1
Certification
Work History
Head of Production, Flublok
Sanofi
Pearl River
01.2025 - Current
- Overall accountability for Flublok manufacturing execution, ensuring compliance with HSE, Quality, and regulatory expectations.
- Leadership of manufacturing managers, technicians, and support functions to ensure safe, reliable vaccine supply.
- Ensured production performance, schedule adherence, deviation management, and CAPA execution while maintaining shopfloor discipline.
- Stabilized operations following a challenging 2024 campaign by driving accountability, reinforcing standards, and shifting the organization from reactive to prevention-focused execution.
- Champion of Sanofi Manufacturing System (SMS 2.0) and cultural transformation on the shopfloor.
- Implemented SMS 2.0 (go-live January 13, 2025) by ensuring leadership participation in workshops and embedding standard performance management tools and routines.
- Built and deployed a skills matrix to accelerate technician qualification, improve flexibility, and support right-first-time execution.
- Developed proactive contamination control strategy by introducing enzymatic cleaning with Realzyme and implementing ATP-based hygiene monitoring for earlier detection and rapid intervention of low-level contamination risks.
- Delivered successful contamination remediation, including implementation of enhanced cleaning and verification practices that supported successful media holds following prior contamination events.
- Strengthened organizational capability through targeted hiring of new skill sets aligned with operational needs and future-state manufacturing requirements.
Interim Head of Production
Sanofi
Pearl River
04.2024 - 12.2024
Manufacturing Excellence Business Partner
Sanofi
Pearl River
11.2020 - 04.2024
- Led site and network-wide deployment of the Sanofi Manufacturing System (SMS) to build a lean, performance-driven culture.
- Led change managers to implement performance management systems that reduced deviations and enabled 100% on-time drug substance delivery.
- Coached senior leaders and shopfloor teams on +QDCI, Daily Capacity Management (DCM), Skills Matrix, Standard Agenda, 5S, Gemba Walks, Flow Control Tower, and deviation management to enhance operational understanding and application.
- Boosted senior leadership shopfloor presence by 50% through implementation of structured Gemba walk programs, fostering direct engagement with teams.
- Facilitated training for over 200 employees in lean principles and practical problem solving to promote a culture of continuous improvement.
Fit4Future Booster Leader
Sanofi
Ridgefield
05.2019 - 11.2020
- Led transformation initiatives in Quality organization, supporting successful ramp-up of new automated packaging line.
- Coached leaders on performance management and visual management, enhancing Gemba-based problem solving capabilities.
- Decreased minor deviation cycle time by 53%.
- Reduced batch record backlog by 93%.
- Coached leaders on performance management, visual management, and Gemba-based problem solving.
Fit4Future Change Leader (Assignment)
Sanofi
Swiftwater
09.2018 - 05.2019
- Led deployment of skills matrix, shutdown readiness, 5S implementation, troubleshooting guides, and reduction of external spending.
- Led cross-functional teams to improve project efficiency and collaboration.
- Conducted lean diagnostics to identify over 25,000 hours of potential efficiency gains.
- Developed strategic plans to enhance market presence and product offerings.
- Coordinated training sessions for staff to boost skills and knowledge.
Facilities Operations Manager
Sanofi
Ridgefield
04.2013 - 09.2018
- Led 18-person facilities team to enhance support for manufacturing operations.
- Managed an 18-person facilities team supporting manufacturing operations.
- Delivered improvement projects end-to-end, including vendor management, budgeting, and execution.
- Fostered collaborative, problem-solving culture that increased reliability and reduced response time.
- Owned deviations, CAPAs, and change controls related to facilities and utilities.
Maintenance / Metrology Supervisor
Sanofi (formerly Genzyme)
Ridgefield
12.2011 - 04.2013
- Supervised maintenance, calibration, and compliance activities for filling, packaging, and sterilization equipment to ensure operational reliability.
- Improved equipment uptime and OEE by 20%.
- Achieved >90% on-time preventive maintenance and calibration compliance.
- Led transition from paper-based MP2 to paperless computerized calibration management system, improving documentation accuracy and accessibility.
- Contributed to development of corporate calibration standard, enhancing consistency and quality across all facilities.
Education
Master of Science - Pharmaceutical Management
Stevens Institute of Technology
Hoboken, NJBachelor of Arts - Economics & History
University of Delaware
Newark, DESkills
- Manufacturing execution
- Lean principles
- Contamination control
- Performance management
- Data analysis
- Change management
- Problem solving
Personal Information
Title: Head of Production (Flublok)
Certification
Lean Six Sigma Black Belt
Timeline
Head of Production, Flublok
Sanofi
01.2025 - Current
Interim Head of Production
Sanofi
04.2024 - 12.2024
Manufacturing Excellence Business Partner
Sanofi
11.2020 - 04.2024
Fit4Future Booster Leader
Sanofi
05.2019 - 11.2020
Fit4Future Change Leader (Assignment)
Sanofi
09.2018 - 05.2019
Facilities Operations Manager
Sanofi
04.2013 - 09.2018
Maintenance / Metrology Supervisor
Sanofi (formerly Genzyme)
12.2011 - 04.2013
Master of Science - Pharmaceutical Management
Stevens Institute of Technology
Bachelor of Arts - Economics & History
University of Delaware