Patrick Malone

Patrick Malone Email and Phone Number

Medical Device Operations | Cultural Transformation | Lean Six Sigma | Continuous Improvement | Talent Development | Ability to Lead Diverse Organizations Across Multiple Sites & Drive Alignment Across Functions @ Catalent Pharma Solutions
somerset, new jersey, united states
Patrick Malone's Location
United States, United States
About Patrick Malone

I am a results-oriented Manufacturing Operations Leader in the medical technology and consumer health industries with demonstrated ability to lead diverse organizations across multiple sites, drive alignment across functions and create a commitment-driven culture in the pursuit of operational excellence. I have a proven track record of continuous improvement and process technology development resulting in greater operational efficiency, improved process capabilities, and a higher level of customer satisfaction.I am known as an experienced multi-site leader and was the Vice President of Operations for West Pharmaceutical Services in Tempe, Arizona. In this role, I had overall responsibility for West’s Contract Manufacturing Operations with sites in Arizona, Michigan, Pennsylvania, Puerto Rico and Dublin, Ireland. I also expanded my responsibility to lead West’s proprietary operations for wearable, subcutaneous drug delivery systems and insert needle syringe systems. Before joining West Pharmaceutical Services, I was an Operations and Engineering leader with Medtronic and was the Site Leader for Medtronic’s Human Tissue Processing facility in Eatontown, New Jersey. I am currently a General Manager at Catalent Pharma Solutions with responsibility for leading Catalent’s Manassas, VA Center of Excellence for Soft Chew and Lozenge manufacturing.

Patrick Malone's Current Company Details
Catalent Pharma Solutions

Catalent Pharma Solutions

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Medical Device Operations | Cultural Transformation | Lean Six Sigma | Continuous Improvement | Talent Development | Ability to Lead Diverse Organizations Across Multiple Sites & Drive Alignment Across Functions
somerset, new jersey, united states
Website:
catalent.com
Employees:
8864
Patrick Malone Work Experience Details
  • Catalent Pharma Solutions
    General Manager
    Catalent Pharma Solutions Mar 2024 - Present
    Manassas, Virginia, United States
    Catalent is a global provider of delivery technologies, development, drug manufacturing, biologics, gene therapies and consumer health products with FY24 revenue of $4.38B.Hired to drive operational excellence and scale manufacturing capacity to deliver business growth projections. Responsible and accountable for leading Catalent’s Manassas, VA Center of Excellence for Soft Chew and Lozenge manufacturing with P&L responsibility for >$50M annual revenue. Developed transformational framework to strengthen leadership, build strong business processes, create a safety-first culture, inculcate a quality mindset and accelerate growth.
  • West Pharmaceutical Services
    Vice President Operations
    West Pharmaceutical Services Feb 2020 - Feb 2023
    Tempe, Arizona
    West Pharma is a global leader in the design and production of technologically advanced, high-quality, integrated containment and delivery systems for injectable medicines. West Pharma’s full-year 2022 net sales were $2.887 billion. Hired to drive Contract Manufacturing margin expansion and scale both CM and Medical Device manufacturing capacity. Led the West Contract Manufacturing Operations and the proprietary manufacturing of wearable, subcutaneous drug delivery systems and insert needle syringe systems. The plant network consisted of a total of seven sites across the US, Puerto Rico, and Dublin, Ireland, with an annual revenue of $600M and over 2,500 team members. Developed, planned, and executed strategic imperatives to deliver annual business objectives.
  • Medtronic
    Site Leader, Medtronic Osteotech
    Medtronic Oct 2014 - Feb 2020
    Eatontown, New Jersey
    Medtronic Eatontown is a global leader in the processing of allograft tissue used for surgical procedures in spinal, orthopedic, sports medicine, and dental applications. Medtronic Eatontown bone grafts have industry-leading osteoinductivity resulting in fusion success. Promoted to drive successful integration of recent acquisition and inculcate the Medtronic operating philosophy, systems, and culture. Accountable to lead all aspects of operations at the Medtronic Eatontown Human Tissue Processing plant. This role involved developing, planning, and executing the site's strategic goals which are aligned with the Restorative Therapies Group (RTG) strategic imperatives. Responsible for leading the tactical execution in all areas of the site including meeting all quality and compliance requirements, driving EHS compliance and results, ensuring customer satisfaction through product supply, establishing and executing annual budgets, and driving continual improvements through the proactive deployment of RTG’s Operational Excellence methodologies and framework. This position is also a member of the American Association of Tissue Banks’ (AATB) Tissue Policy Group.
  • Medtronic
    Director, Tempe Manufacturing Operations
    Medtronic 2008 - Oct 2014
    Tempe, Az
    Medtronic Tempe Campus designs, develops, manufactures, and tests microelectronic solutions used in Medtronic implantable devices, such as cardiac pacemakers and defibrillators, spinal cord stimulators for pain management, and deep brain stimulators that address movement disorders. Accountable to lead the Tempe Campus Manufacturing Operations in the manufacturing of Medtronic’s implantable pacemakers, defibrillators, and neuromodulators. Responsibilities included leading the Electronic Hybrid Assembly and Test, Wafer Probe, and Die Prep production operations across four shifts (24/7), manufacturing engineering, new product introduction, Lean Sigma, manufacturing program management, equipment maintenance engineering, automation engineering, logistics, and planning teams. • Provided manufacturing leadership to drive performance excellence culture and achieve first-pass quality.• Improved direct labor productivity by over 110%, achieved a 40% product cost reduction, increased capital asset utilization by over 90%, and achieved improvement in inventory turns of over 50%.• Achieved No Rework cultural transformation eliminating rework across all products.• Implemented a 12-hour production shift structure to improve operational efficiency and achieve $1.2M in annual savings.• Executed Product Portfolio Rationalization Strategy eliminating low-volume products and streamlining business to achieve a $10 to $15M annual savings.• Established physical and organizational value stream alignment across key product families and created the Tempe Value Stream Operating System.• Integrated standardized problem-solving tools (ProST) across the entire production team and established a ProST certification process for production associates.• Created a quarterly Manufacturing Continuous Improvement Forum to allow production associates to share their key project results and discoveries with other team members.
  • Medtronic
    Director, Hybrid Electronic Manufacturing
    Medtronic 2001 - 2008
    Tempe, Az
    Leader of more than 500 employees in the electronic hybrid manufacturing operation for implantable pacemakers, defibrillators, and neurostimulators. Responsibilities included leading production operations across five shifts (24/7), process engineering, process development engineering, Lean Sigma, and equipment engineering teams. • Provided operational and engineering leadership to drive continuous improvement culture leveraging Lean Sigma Methodologies. • Improved operational productivity and plant capacity to support annual business growth of 10 to 20%.• Fostered Lean Sigma culture to reduce product lead time by over 65% and continuously improve product yields resulting in $9M scrap avoidance.• Completed a $9M hybrid electronic manufacturing expansion to create a lean low-power manufacturing line and establish business continuity for electronic assembly and test operations. Achieved a 60% reduction in part travel distance and a 65% reduction in direct labor. • Created a highly responsive and flexible manufacturing organization capable of rapidly supporting changes in the business environment.• Aligned the manufacturing organization with new product development ensuring new processes were successfully introduced according to the project plan.• Developed organizational values to align a diverse workforce and established a recognition program rewarding behaviors consistent with these values.
  • Medtronic
    Department Manager, Metalized Ceramic Operations
    Medtronic 1999 - 2001
    Tempe, Az
    Leader of 90 people in engineering and operations for metalized substrate manufacturing. Specific responsibilities included managing production operations, planning, process engineering, maintenance, and equipment engineering. Set departmental vision as assembly technology shifted toward printed circuit boards, managed reduction in personnel while maintaining positive department morale, and ensured area critical success factors continued to be achieved during the transitional period.
  • Medtronic
    Engineering Manager, Metalized Ceramic Operations
    Medtronic 1995 - 1999
    Tempe, Az
    Led process engineering group in achieving a two percent yield improvement per year, as area yield exceeded 92%. Developed yield incentive program which focused on weekly yields and created a sense of urgency to address yield issues in a timely manner. Developed capability to regularly deliver new product prototypes with less than one week cycle times. Consistently shifted the responsibilities within engineering group as people transitioned from the area. The changes ensured adequate production coverage was always maintained while also increasing the breadth of knowledge of the process engineering team.
  • Tempe Ymca
    Board Of Directors
    Tempe Ymca 1998 - 2001
    Tempe, Az

Patrick Malone Education Details

Frequently Asked Questions about Patrick Malone

What company does Patrick Malone work for?

Patrick Malone works for Catalent Pharma Solutions

What is Patrick Malone's role at the current company?

Patrick Malone's current role is Medical Device Operations | Cultural Transformation | Lean Six Sigma | Continuous Improvement | Talent Development | Ability to Lead Diverse Organizations Across Multiple Sites & Drive Alignment Across Functions.

What schools did Patrick Malone attend?

Patrick Malone attended Arizona State University, W. P. Carey School Of Business, Alfred University, Alfred University.

Who are Patrick Malone's colleagues?

Patrick Malone's colleagues are Karen Mortimer, Megan Lynn, Ferdinand Regaspi, Giulia Sportelli, Erin Bellhorn, Mariangela De Vito, Alberto Conceicao.

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