Greg Fallon Email & Phone Number

Grand Rapids, MI, US

Grand Rapids, Michigan, United States

Ada, Michigan, United States

• Directed a global Supply Chain initiative with a $20M capital budget in an executive development assignment. In addition, led the Manufacturing Training and Development team. Devised and evaluated numerous plant.
• Completed rollout of new Manufacturing Workforce System and Skill Development System
• Challenged project assumptions that led analysis to recommend suspension of project and re-allocation of capital

Greater Grand Rapids, Michigan Area

• Led nutritional powder manufacturing and warehousing operations that generate over $500M in annual revenue. Planned and managed annual operational budget and multiple capital project budgets in alignment with strategic.
• Improved safety culture to see recordable incidents reduced from 9.8 TRIR in 2017 to 1.9 TRIR in 2021
• Transformed delivery results from 84% Schedule Adherence (weekly volume) to 101%, with increased volume
• Drove efficiency improvement and closed service level gap, from 4% of product unavailable to less than 1%
• Led cross-functional team to reduce air shipment cost from $2.5M to less than $750k annually
• Transformed all end-of-line packaging to collaborative robot automation with a 22% ROI

Ada, MI

• Partnered with printing operation supplying six manufacturing operations with cartons, labels, and literature. Led a team of eleven salaried staff responsible for production scheduling, capacity planning, customer.
• Reduced headcount and SG&A spend by 20% while processing 37% more Work Orders annually
• Insourced Nutrition labeling while achieving HP’s #1 global ranking for digital label printers
• Built culture of variance and cost reduction from $3.7M unfavorable in 2016 to $1M in 2017 and $0 in 2018

• Oversaw manufacturing floor operations in Packaging and Process/Mix functional areas for cosmetics CPG manufacturing facility. Established production schedules and staffing requirements in partnership with supply chain.
• Led global leadership team to implement breakthrough new Safety Excellence program in manufacturing to achieve OSHA audit requirements
• Created Line Performance Program to exceed results on Changeover, Ramp-up, Throughput, and Total Cost Productivity

• Established processes and procedures to improve quality for high-precision machining manufacturer supporting medical device and automotive industries. Owned health of quality assurance systems and quality control.
• Led Quality department to ISO 13485:2003 and 9001:2008 registration for the first time
• Invested in advanced metrology systems that reduced inspection time and exceeded customer specifications
• Insourced FDA approved chemical systems, including electrochemical deburr, electropolishing, and passivation
• Transformed quality culture, resulting in reducing defective product returns from 1.7% in 2010 to 0.6% in 2011

Formulated Light-Activated Shape Memory Polymer in a team environment to achieve project objectivesCharacterized polymer samples and optimized formulations based on test resultsFabricated unique samples in a variety of projects

Investigated softgel shell hardness corollaries to determine proper drying phase endpointDeveloped test methods for accurately analyzing shell hardness corollariesSupervised softgel production at contract manufacturing plants to ensure consistent quality and study production processEstablished softgel process specifications to support new softgel facility

Supported various engineering teams in problem-solving projects Analyzed materials through failure analysis testing as part of a development teamOrganized test panel and test coupon assembly planning and helped coordinate shipments to and from testing facilities

Optimized current detergent formula for improved secondary benefits as part of the future Home Care business planAnalyzed dye loss and dye transfer characteristics of various textilesCompared effectiveness of potential formulas to various competitors and benchmarks Proposed future product specifications in end-of-summer presentation

Master Of Business Administration - Mba, Business Administration And Management, General

Bachelor, Chemical Engineering

Activities and Societies: AIChE, SAMPE