Philip Tocco Email & Phone Number

Erie, Co, Us

Boulder, Colorado, United States

As Manufacturing Operations Director, I led transformative changes that drove $301M in production and contributed to $1.7B in annual revenue. By optimizing manufacturing processes, I improved labor efficiencies from 100% to 124%, surpassing goals by 15%, and reduced backorders from 11 weeks to 3 weeks, generating $50M in revenue. My efforts in culture transformation through people programs, communication, and training resulted in a 5% annual improvement in engagement survey results and record low turnover. Additionally, I guided the organization through a significant MES system transition across 15 production value streams, enhancing operational efficiency. This was all achieved while managing one of Medtronic's largest manufacturing sites, leading a team of 660 in a 450K sq. ft. facility.

Louisville, Colorado

As Director of Operations/Site Leader, I led a team of 80 in an 82K sq. ft. facility, driving $500M in annual revenue and managing $115M in production costs. By optimizing processes and managing the Global Distribution Center, D2C, and International Make-to-Order operating system, I delivered over $10M in cost savings and reduced backorders by $2M. My leadership was instrumental in reshaping the culture at the manufacturing site, transforming it from a small site in a competitive bidding environment to a leading facility in next-generation robotic manufacturing. Under my direction, we achieved world-class 89% organizational health survey results and won runner-up for Corporate Site Cost Efficiency Management out of 70 sites. My efforts laid the foundation for the site's recognition as the small site runner-up in the Manufacturing Cup for 2024, reflecting the exceptional results and strong operational framework established during my tenure. Additionally, I improved diversity and equity scores to 91%, fostering an inclusive and innovative workplace.

Neenah, Wisconsin

As Senior Manufacturing Operations Manager, I led a department of 250+ operations and engineering team members in a unionized workforce, managing a $55MM budget to achieve benchmark results in safety, quality, delivery, and cost. I spearheaded the department strategy, engaging and empowering the broader operations and maintenance organization to drive down changeover delays to record levels. My leadership was pivotal in the site's cost transformation efforts, resulting in a 12% waste reduction, $1.1MM reduction in spending, and a 10% reduction in cost per unit. Additionally, I played a crucial role in labor relations and negotiations with the union, fostering a collaborative environment. Managing a single-sourced operation for one of Kimberly-Clark's billion-dollar brands, I ensured the department consistently exceeded performance targets, driving overall manufacturing success and efficiency

Neenah, Wisconsin

As Operational Excellence Sector Leader, I partnered with McKinsey Consulting to develop and deploy 'One-Best-Way' to achieve Operational Excellence, leading a multi-year culture transformation strategy that boosted productivity across a 3,500+ person organization and contributed to $100MM in capital avoidance. By standardizing operating and continuous improvement systems, I reduced productivity variability across 116 assets, increasing annual OEE targets by 25%. I inspired a people-centric cultural movement, resulting in the development of 5 operational leadership principles and a 10% increase in organizational health survey scores. My leadership influenced a sector-wide OPEX strategy adjustment, solving 30 systemic problems and raising management infrastructure health check scores by 40%. I built a high-performing 50-person Lean Change Agent organization with expertise in leading kaizen workshops, which also served as internal consultants for 11 manufacturing sites.

Tulsa, Oklahoma Area

As Lean Continuous Improvement Site Leader, I drove performance improvements using Lean techniques, leading to a 20% productivity increase. I identified opportunities with Lean assessment tools, integrating them into acceleration plans and coaching teams through problem-solving activities. I managed tools and processes for an OEE transformation and led a change team that deployed successful OPEX transformations across departments. I facilitated a fire and flood kaizen workshop, securing over $2M in capital for a fire suppression system, and addressed grade change delays for a billion-dollar brand new product introduction, leading to a vertical start-up. Additionally, I led tissue machine autonomous care kaizen workshops that improved reliability and eliminated defects across multiple mills. As Co-Chair for the Annual United Way Fundraising Drive, I generated $500K in donations to the United Way Charity, demonstrating my commitment to community and social responsibility.

Conway, Arkansas

As Manufacturing Team Leader, I led the start-up of a $22M expansion department and managed a $12M annual budget. I established a best-in-class culture, achieving $700K in annual sourcing savings and eliminating 100% of tractor/pedestrian hazards through improved staging systems. I executed the most successful vertical start-up in the sector's history, delivering $1.5M in annual savings and exceeding all performance objectives. I led a cross-functional team to deliver $4.4M in enterprise cost savings and supported a record sales month of $3.4M. Additionally, I received a corporate award for implementing best-in-class TPM and Centerlining systems. My initiatives reduced changeover time by 75%, driving significant efficiency gains and $100M in working capital savings

Conway, Arkansas

As Manufacturing Team Leader, I coordinated Sustaining Engineering project rollouts and conversion schedules for new product introductions, improving team efficiencies with a standard weekly scheduling process. I developed a loading strategy that saved $1M annually in distribution costs. Leading a team with an $11M annual budget, I achieved safety, quality, delivery, cost, and Lean objectives. I facilitated 5S training and housekeeping workshops, improving scores by 40% and closing 65% more safety notifications. My initiatives, including addressing consumer complaints and establishing 24/7 operator-owned grade change capability, resulted in record low complaints and $100M in working capital savings. Additionally, I led a cost-saving project for low-count packaging, saving $250M annually, and developed processes to reduce waste and build skills through Lean workshops.

Neenah, Wisconsin

As Strategic Capacity Requirements Planner, I coordinated project conversion schedules and rollout plans for new product introductions, providing daily direction to Mill Production Schedulers to manage inventory mix and business initiatives. I utilized Lean principles to enhance stock availability and customer service, and led efforts to execute $62M in Cost Reduction Initiatives by developing curtailment plans and providing weekly working capital updates. I exceeded the obsolete inventory target, keeping it below 1% of annual gross sales. I improved team efficiencies with a standard weekly scheduling process and developed a loading strategy that saved $1M annually in distribution costs. Additionally, I led monthly capacity reviews to support new distribution initiatives.

Neenah, Wisconsin

As Strategic Materials Requirements Planner, I provided long-term forecasts to internal and external vendors, acting as a liaison between Tactical Scheduling, Centralized Material Planning, Strategic Planning, Purchasing, Mill Operations, and Engineering. I led efforts to deplete $1M of obsolete and slow-moving raw materials through customer and supplier negotiations. By implementing Lean initiatives and standard processes within external operations supply chains, I reduced raw material working capital inventories by $2.9M. I provided work direction to Material Planners to minimize downtime and successfully execute initiatives. Additionally, I developed new standard processes for raw material procurement, vendor waste management, production scheduling, rollover execution, and external operations management, improving team productivity.

Neenah, Wisconsin

As Master Production Scheduler, I scheduled global network tissue manufacturing lines to ensure 100% base roll support for internal and external converting. By implementing Lean Manufacturing schedules, I increased productivity, reduced total grade change time, and freed up 20% of the workforce for cost reduction initiatives. I managed product rollovers and new product introductions, including contract manufacturing expansion efforts in Europe, Asia, and Australia. I increased Trailer on Flat Car (TOFC) shipments, saving $400K annually. Collaborating with suppliers, I procured raw materials to support tissue machine schedules with zero shutdowns. Additionally, I managed SAP/APO transitions across 8 tissue machines to ensure 100% wadding support.

Knoxville, Tennessee Area

As Transportation Analyst, I was responsible for the movement of products to and from production facilities, warehouses, and customers. I used my analytical, problem-solving, and communication skills to balance cost, quality, and service trade-offs. I exceeded the objective to acquire 99% truck load capacity, supporting enterprise growth with on-time pick-up. By creating capacity for high-quality, low-cost carriers, I reduced total North East freight costs by 19%. I supported customer development strategies with consistent on-time deliveries, ensuring high service levels. My efforts contributed to the overall efficiency and cost-effectiveness of transportation operations

As a Logistics Transportation Analyst, I improved truck utilization by 6% using software to manage LTL shipments from supplier to customer. I ensured efficient movement of products across production facilities, warehouses, and customers, balancing cost, quality, and service. My analytical and problem-solving skills supported enterprise growth by securing 99% truck load capacity with on-time pick-ups.

Education record

Supply Chain Management, Business

Activities and Societies: Boeing Company Supply Chain Management Scholarship, recipient National Society of Collegiate Scholars, member.