CAPABILITIES Barrier Material SelectionsCost ReductionsCreative Structural Packaging DesignDesign of Experiment (DOE’s)Equipment SelectionFlexible Pouches (coated/uncoated substrates)Form, Fill, & Seal Machines - selectionHeader pouchesLabeling Compliance for CE MarkMaterial Evaluation and SpecificationOutsourcing ProgramsPackage and Process Validation ProceduresProblem SolvingProduct & Package Cost EstimatingProject ManagementShipping Test ProceduresSupplier Selection and AuditingThermoforming Rigid TraysTray Sealers & Required Tooling

Lyons fabricates precision metal stamping dies for the medical, automotive, defense, and electronic industries. AS9100 and ISO13485:2016 certified with a focus on rapid prototyping utilizing state-of-the-art equipment and an innovative engineering team.

Datascope Corporation, Interventional Products and InterVascular Divisions, Mahwah, NJ Vice President, Operations (2004 – 2005)Reporting to President, directed all areas of Operations for Datascope’s Interventional and InterVascular divisions including manufacturing plants in La Ciotat, France and Mahwah, NJ. Responsibilities included:Planning, purchasing, logistics, processing activities that support company’s operations including locating slaughterhouses in New Zealand and Australia for tendon procurement for collagen process.Member of senior management team that developed objectives, strategies and policies for the division.Orchestrated team to implement over $2.6 million in cost reductions and new business development initiatives.Operations team leader for all due diligence activities.

Directed all areas of packaging, packaging graphics and documentation. Accountable to multiple plants (i.e.; Puerto Rico, The Dominican Republic, Mexico, United Kingdom, and US) to ensure products were manufactured in compliance with FDA, OSHA, and ISO11607 guidelines. Coordinated multi-functional team to merge USS and D&G suture manufacturing companies (totaling $250M in sales) into one consolidated product line, offering the best quality to the customer in the most acceptable configuration. Reduced packaging costs $500,000 annually by reducing or changing raw materials, transferring blister forming of rigid trays in house, and using lean manufacturing techniques to reduce assembly costs.Worked with purchasing in strategic sourcing initiatives. Consolidated supplier base and partnership with remaining suppliers to reduce costs. Participated on acquisition teams in the transfer of products and technology.

Directed all packaging, graphics, industrial engineering and documentation activities throughout the corporation. Also responsible for raw material warehouse and logistics activities. Coordinated cost reduction program generating $50M savings over a 2-year period. Strategically sourced high cost raw materials and eliminated duplicate suppliers.Coordinated Operations due diligence team on new acquisitions. Provided product cost analyses and production capabilities, including product ramp up, tooling capabilities and profit margins. Purchased thermoformers to thermoform rigid PETG trays in house. Realized 80% reduction in warehouse space, 40-50% savings in part cost, and created a demand pull system using kanbans. Developed Packaging Environmental Program focusing on size reduction to reduce waste. Developed new suture packaging including a foil pouch design that minimized moisture transmission (MVTR) while providing the Market a new concept in suture packaging.