Joe Mollica

Leads continuous improvement and lean transformation initiatives across manufacturing and automated production lines to reduce costs and improve throughput. Implements production control systems such as Just-in-Time, Kaizen, Kanban, 5S, SPC, PFMEA/DFMEA and CAPA, tracking KPIs and driving Lean Six Sigma practices. Manages simultaneous manufacturing projects, including supplier/client contract negotiations, scheduling, URS/specifications for production equipment, and equipment installation, testing and qualification.

Manages contracted improvement projects covering production, maintenance and process/machinery design with an emphasis on reducing costs and preparing for plant expansion. Oversees cross-site subcontracting, project scheduling, budgets, resources and risks, and coordinates delivery tracking with suppliers and contractors. Produces URS documents for packaging and assembly equipment, supports FAT/SAT/OQ/IQ planning, and manages installation and qualification of production equipment and lines.

Supported continuous improvement for supply chain and manufacturing operations, focusing on cost reduction and process optimization. Coordinated outsourcing and multiple projects across supply chain, logistics, and production for new product introductions in the United States and Montreal. Managed supplier qualification and tendering, contract and budget review, and project planning including risks and resources. Oversaw equipment installation, testing, and production line commissioning activities.

Leads production and operations across multiple departments, including production PVA, manufacturing engineering, quality control, inventory/procurement, maintenance, shipping, and documentation. Implements quality and continuous improvement systems (Lean Six Sigma, PVA, CAPA, 5S, Kaizen, ISO 9000/9001) and drives process and production improvements using structured planning such as MRP. Manages budgets and project portfolios, coordinates weekly production meetings, and plans customer order execution and operating schedules.

Led and trained 150+ employees and managed multiple departments covering operations, supply chain, logistics, production, and engineering improvements. Implemented quality control systems and improvement programs including Lean Six Sigma, PVA, 5S, KPIs, Kaizen, and ISO 9000. Managed manufacturing and maintenance budgets and R&D project planning, schedules, and resources. Participated in supplier and subcontractor selection and coordinated weekly production and repair planning.

Managed and developed teams across operations, supply chain, logistics, production, quality, and inventory for new product introductions. Optimized supply chain performance using operational data and supported supplier qualification. Owned profitability and production budgeting including OPEX and CAPEX, and created factory plans for automation equipment deployment. Implemented JIT, SMED, Kaizen, Kanban, PPAP/APQP, PFMEA/DFMEA, 5S, DMAIC, VSM, and performed design/automation tooling and component stress analysis.

Wrote manufacturing methods for aircraft infrastructure components for Bombardier Aerospace projects. Coordinated between departments to support delivery of engineering and manufacturing projects. Worked during a restructuring period that included staff reductions.

Manages production, maintenance and administration activities for a lobe-type pump manufacturer and coordinates shipping, proposals, logistics, procurement and quality. Implements JIT, Kaizen, PFMEA and Lean Six Sigma practices while tracking KPIs and negotiating supplier/customer contracts. Contributes to design and development of pump product lines and supports software and MRP development for sales and production planning, along with manufacturing line setup.

Oversees contracted bids, production execution and quality for non-destructive testing systems and supports Kaizen/TQM-based improvements. Directs designers and manufacturing personnel, including technical and mechanical design analysis for test equipment and new probe development. Introduces the product to manufacturing by designing tooling fixtures, applies PFMEA/DFMEA and SMED approaches, and supports qualification through structured engineering execution.

Designed and drafted R&D improvements for electrical switching control devices and mechanical packaging. Focused on improving operational efficiency, mechanical integrity, and reducing production costs while making assembly easier. Delivered engineering drawings and design changes as part of contracted development work.

Managed procurement, bids, and quality work and implemented a JIT/Kanban-style operational improvement approach with Kaizen, PFMEA, and KPI tracking. Led designers and production staff and contributed to development of a new lobe pump product series. Supported engineering systems for selecting controls and auxiliary components and assisted with manufacturing/assembly line introduction. Authored technical FAIR/LAIR review reports as part of product/process documentation.

Ran an earned value project to develop an industrial burner prototype aimed at reducing pollution from industrial effluent processes. Built project schedules and budgets, managed subcontractors for purchasing and prototype fabrication, and resolved manufacturing and JIT issues. Conducted technical trials, wrote operational procedure documentation, and guided quality control and product introduction to manufacturing. Also designed and managed additional equipment improvements including a heat exchanger, pumping system, and conveyor.

Managed bids, procurement, manufacturing and quality work, applying continuous improvement approaches. Analyzed supply chain data and coordinated engineering and production activities with designers and team members. Designed and technically evaluated non-destructive testing equipment and related mechanical components, including an ultrasonic probe concept. Introduced the product to manufacturing and supported fixture design, with PFMEA/DFMEA and SMED activities.

Participated in the design of gas turbine components, creating detailed CAD design outputs. Supported manufacturing process definition and refinement through review of fabrication methods. Performed stress-related analysis and produced design documentation for the project deliverables.

Managed multiple projects using earned value methods and coordinated indirect staff across manufacturing, engineering, R&D, and QA. Handled bids, production/quality activities, SMED, and quality KPI tracking to support product market introduction timing. Set up ISO 9000 and PFMEA/DFMEA and established product and manufacturing design parameters. Designed product and packaging innovations using ProEngineer and AutoCAD, supported feasibility and cost reduction analysis, and helped manage product certification activities.