John Kay Email & Phone Number

Engaged to fill positions from interim COO to project management. Servicing companies that are Private Equity, Private and Publicly owned. Assignments focus on leading day to day operations while transforming leadership into high functioning teams. Implementing change management and lean six-sigma while driving EBITDA improvement.

Louisville, Ky , Us

LLFlex is a global leader in packaging materials and industrial laminate solutions for the consumer packaging, building & construction, and wire & cable industries.Responsible for developing and executing the company’s operations strategy, overseeing day-to-day operations, and collaborating with the CEO and Executive Team to support the organization at a time of rapid organic and external growth.

San Antonio, Texas, Us

HVHC is an integrated optical company with $1.7B in annual revenues and 5K+ employees.As Executive Vice President for Manufacturing & Distribution, I was recruited to transform the manufacturing organization supporting our Visionworks (retail optical stores), Visionworks.com (e-commerce), and Davis Vision (managed vision care) divisions. I oversaw 4 manufacturing facilities and 2 distribution centers supplying 750+ retail locations and 17K eye care professionals across the U.S. I implemented lean six-sigma methodologies, created a culture of accountability, and delivered outstanding customer experience while leading 1K+ employees.Some of the key ways in which I made a difference include:FINANCIAL OUTPERFORMANCE / PROCESS OPTIMIZATION► Reduced unit cost of production 27%+ from $22 to <$16 (per pair of glasses) while expanding output capacity 38% from 4M pairs in 2011 to 5.5M pairs in 2018, boosting EBITDA $30M.► Built new manufacturing and distribution center with lean six sigma principles embedded in design and construction, allowing for 40% lower headcount as compared to legacy facilities.► Slashed annual inventory write-offs from $400K to < $20K while attaining order processing accuracy of 99.98%+.► Established Kanban system to reduce necessary levels of ancillary supplies from 2+ months to < 2 weeks.► Implemented activity-based costing across all manufacturing and distribution, providing granular insight into true cost of all products to determine optimal pricing and maintain margins in market with downward pricing pressure.► Played instrumental role in sale of Davis Vision to Centerbridge Partners by creating operational infrastructure and culture of manufacturing excellence to position company for significant future growth.

San Antonio, Texas, Us

(CONT’D FROM ROLE ABOVE)GREEN INITIATIVES / HEALTH & SAFETY / REGULATORY COMPLIANCE► Lowered number of annual workplace injuries 66% and ensuring 100% regulatory compliance across all facilities.► Piloted new green technologies at facilities, saving $250K+ annually and resulting in successful removal from state of Texas’s Large Quantity Generator (LQG) of hazardous waste list.► Worked closely with Essilor and other OEMs to implement new alloy replacement technology, enhancing workplace safety while reducing environmental impact.CUSTOMER SATISFACTION / QUALITY ASSURANCE► Turned around faltering client relationship with Federal Employee Plan (FEP) by delivering top quality products within expedited timeframe, successfully retaining account generating $60M+ in annual revenues for HVHC.► Cut annual losses due to internal scrapping of products 65% to save $5M each year and slashed defect rate of goods delivered to customers from 3% to 1%, reducing customer quality complaints 68%.► Revamped call center operations, dramatically improving response time from 72% of calls returned within 24 hours to 100% of calls returned in < 3 hours with 20% lower headcount.

Somerset, Nj, Us

Catalent Pharma Solutions is a global provider of oral and sterile delivery systems with $1.5B in annual revenues and 5K+ employees.As Vice President of Operations for Printed Components & Clinical Services, I was hired to execute a rapid turnaround of 8 underperforming manufacturing facilities supplying our Printed Components and Clinical Services divisions. I oversaw operations in the U.S., Puerto Rico, Ireland, the U.K., and Germany. In this role, I led 1.2K employees.My impact on the business:► Significantly reduced unit costs, producing 1.1B units in 2008 at cost of $97M v. 1.5B units in 2011 at $87M in costs.► Developed sophisticated contract bid process, allowing for rapid, accurate, and profitable pricing of potential client mandates and enabling commercial team to grow revenues 20%.► Reduced overall fixed costs $11M and cut variable costs 25%+ across 4 printed components facilities.► Shut down unionized facility and consolidated operations with nearby non-unionized facility. Transferred contract-packaging operations in Puerto Rico to U.S., improving EBITDA by $5M. ► Nearly eliminated recordable workplace incidents from 6.20 to 1.09 per year, slashed required inventory levels from 60 days to just 2 weeks, and lowered internal product scrap rate 30%+.

Bachelor Of Science, Mechanical Engineering

Master Of Business Administration, Operations Management & Finance