Stephen N. Mercadante___(732) 275-6575 sm10f685c@westpost.

net
23 Borden Road, Middletown, NJ http://www.linkedin.com/in/mercforcontinuousimp
rovement

PROFILE:
Extensive experience managing manufacturing operations and applying lean and six
sigma tools to drive change
resulting in reduced costs and cycle time, higher profit margins, and improved s
ervice. Seeking to
design a high energy team and instill a culture of continuous improvement.
AWARDS & RECOGNITION:
Recognized at Osteotech Annual Employee Meeting for leading Lean initiative resu
lting in $5M savings.
Trained 500 technicians in Lean and good manufacturing practices, Cordis Preside
ntas award.
Awarded first prize for improving 10 critical processes saving
$500K at GEC division wide celebration.
US patent 6,622,864 B1, thermoformed tray package with improved customer satisfa
ction.
SKILLS:
Safety a" Experienced in creating a safety culture to prevent OSHA recordables i
ncluding safety cross, job safety analysis, near miss, behavioral audits, MSDS,
safety improvement opportunity, and ergonomics.
Quality a" Advocate of the quality system to document, investigate, identify and
mitigate quality system deficiencies with a strong focus on prevention and resp
onding to customer issues.
Continuous Improvement a" Successful application of lean and six sigma improveme
nt methodologies across regulated industries including commercial electronics, m
edical devices and aerospace electronics.
Production Management a" Extensive experience managing and controlling productio
n output and quality to improve service and meet targeted revenue through the ap
plication of lean and kaizen.
Industrial Engineering a" Experienced in establishing SAP business system includ
ing routers, bills of material, standard costs, work center capacity, material u
tilization, and performance reports.
Regulatory Standards Compliance a" 21 CFR part 11, 814, 820, 821, 1271; IPC clas
s 2, IPC class 3.

EXPERIENCE:
Cooper Notification, Long Branch, New Jersey. 2/2010-Present
$50 Mil Sales in electronics manufacturing and packaging of mass notification an
d life safety systems.
Production Manager
Manage 5 team leaders, planning, scheduling and 100+ union employees of diverse
backgrounds in high mix, $300K daily ship, in manufacturing, test, inspection an
d packaging of mass notification and life safety systems. Utilize SAP business
system and BW reports.
Drive safety improvements resulting in reduced incident rate and OSHA recordable
to best in corporation through change in work practices, implementation of 6S,
daily toolbox talks, safety cross, gemba walks, safety improvement opportunitie
s, JSAas and behavioral audits.
Led productivity improvements resulting in 40% increase to first pass yield and
2% productivity gain through kaizen events, set up reduction, supermarket design
, improvements to flow, replenishment, and warehouse management, daily gemba wal
ks, success metrics and rail charts, preventive maintenance improvements, new sk
ills training and standard work practices.
Improved service and on time delivery by 35% through the creation of standard wo
rk practices, SAP work outs, new planning reports and metrics, reduction in mate
rial outages, production interrupts and work arounds, improved flow and schedule
attainment.
Hold monthly communication meetings with entire shop to review highlights for sa
fety, quality, delivery, inventory, cost, and service awards.
Osteotech, Eatontown, New Jersey. 1998-10/2009$100M Sales in manufacturing and
packaging of biologic and device systems.
Director Support Services 2006-2009
Directed 35 employees in aseptic manufacturing including Validation and Packagin
g Engineering, Sanitization, Sterilization, Sterile Supply, Packaging and Labeli
ng. $4M Budget, $1M Capital.
Stephen N. Mercadante (732) 275-6575
Led Lean manufacturing strategy and change management process, performed trainin
g and led kaizen events to achieve $2M in savings in cycle time, inventory reduc
tions and material yield improvements.
Chaired weekly Sales & Operations meeting and monitored progress for pull system
. Assigned action items, performed root cause analysis to mitigate back orders,
improve delivery and inventory targets.
Validated packaging to extend product shelf life saving $450K and consolidations
saving $100K. Supported packaging (bottles, thermoforms, vacuum) for solids an
d gels.
Director Facilities Engineering 2003-2006
Directed Facilities Engineers, Maintenance, Calibration, Safety and Health and c
ontract services for 4 buildings including 75,000 square feet of clean room. De
veloped 5 year master plan and executed build out of clean rooms and warehouse c
onsolidation to anticipate changes in product mix and demand. Improved reliabil
ity of critical systems. $6M budget, $4M capital.
Reduced critical alarms and improved response by 50% through the validation of J
ohnson Controls building monitoring system and establishing action and alert lim
its and response protocols.
Led transition of manufacturing operations to a new $55M design build facility,
including fit out and commission of critical systems (Water, Power, HVAC) withou
t interruption to customer demand.
Process Engineering Manager 1998-2003
Established Process Engineering department consisting of Chemical, Mechanical an
d Industrial Engineers. Performed product development and transfer, process imp
rovements, packaging engineering and validations. Established standards, router
s and material utilization for SAP business system.
Led development, designed experiments, installation and validation of new techno
logies resulting in improved process capabilities (Cpk), 50% set up reduction an
d increases to material yield.
Improved manufacturability of new product designs through the application of six
sigma tools resulting in robust process capabilities (Cpk > 1.33) prior to mark
et launch.
Cordis, a Johnson & Johnson Company, Warren, New Jersey.
1995-1998
$500M Sales in manufacturing and packaging of medical devices.
Operations Team Leader
Supervised 110 technicians in the manufacture of a medical device in high volume
, FDA regulated clean room environment. Established kanbans and safety stock an
d utilized SAP business system.
Strategically planned and implemented Lean for Coronary products saving $5M and
increased efficiency from 24/7 to 2 shift operation.
Implemented SPC for balloon and extrusion, resulting in a 15% yield improvement
and set-up reduction.
GEC Marconi plc, Electronic Systems (formerly Singer Kearfott), Wayne, New Jerse
y. 1981-1995
$3.5B Sales in development and manufacturing of aerospace and electronic defense
systems.
Supervisor, Manufacturing Engineering
Supervised 25 engineers in Methods, Tooling, Industrial Engineering, Facility La
youts and Skills Training. Generated methods, routings, staffing, should costs,
tooling for assembly, inspection and test.
Cost reduced major products resulting in $500K savings through operations analys
es and videotape.
Established a total quality management culture including mission statement, TQM
organization, training, awards and recognition, newsletter, 6 Sigma, critical bu
siness processes and process action teams.
EDUCATION: MBA Management, Fairleigh Dickinson University, Teaneck, New Jersey
BS Industrial Engineering, New Jersey Institute of Technology, Newark, New Jerse
y
OTHER:Design for Six Sigma Manufacturability, Motorola Inc.
Green Belt Certification, Rutgers New Brunswick, NJ.
Adjunct Professor of Business Statistics, Seton Hall University,1998.
3 Years of Spanish