Manufacturing Expertise

Plant Manager | Production Operations Executive

Over 20 years of hands-on manufacturing expertise across renewable energy, industrial heating, automotive, and bioethanol production industries.

Manufacturing Approach Download CV

Manufacturing Expertise Overview

Comprehensive manufacturing knowledge across diverse production environments

Roberto Potenza Manufacturing Operations

Manufacturing Operations Specialist

With over two decades of hands-on manufacturing experience, I have developed deep expertise in plant management, production optimization, and manufacturing operations across multiple industries. My manufacturing knowledge encompasses the entire production lifecycle from raw materials to finished products, with particular emphasis on process optimization, quality control, and continuous improvement.

My manufacturing expertise has been applied across diverse production environments including:

  • Renewable Energy Production: Renewable natural gas facilities at Opal Fuels
  • Industrial Heating Manufacturing: Heating element production at Chromalox
  • Automotive Component Production: Vehicle parts manufacturing at Faurecia
  • Bioethanol Production: Biofuel manufacturing at Abengoa Bioenergia

This diverse manufacturing background has equipped me with versatile expertise that can be applied across various production environments, from discrete manufacturing to continuous process operations.

Manufacturing Approach

My methodology for optimizing manufacturing operations

Process Optimization

My approach to manufacturing process optimization begins with comprehensive value stream mapping to identify bottlenecks, waste, and improvement opportunities. By applying lean manufacturing principles and industrial engineering techniques, I systematically enhance production flow, reduce cycle times, and increase throughput.

This methodical approach to process optimization has enabled me to achieve significant improvements in manufacturing performance, including a 34% increase in plant output at Chromalox while maintaining exceptional quality standards and employee engagement.

Quality Management Systems

I believe that quality must be built into manufacturing processes rather than inspected afterward. My approach to quality management involves implementing robust quality systems that emphasize prevention, statistical process control, and continuous monitoring. As an ISO 9001 Lead Auditor, I've developed and implemented comprehensive quality management systems that ensure consistent product quality while minimizing inspection costs.

By establishing clear quality standards, implementing effective measurement systems, and fostering a quality-focused culture, I've successfully maintained exceptional quality performance even during periods of significant production growth and change.

Manufacturing Technology Integration

I embrace the strategic integration of technology to enhance manufacturing operations. My approach involves evaluating production technologies based on their potential to improve efficiency, quality, and flexibility while considering implementation complexity and return on investment. I've successfully implemented various manufacturing technologies including automated production equipment, real-time monitoring systems, and digital work instructions.

By taking a balanced approach to technology adoption—implementing solutions that deliver tangible benefits without unnecessary complexity—I've helped manufacturing operations achieve significant performance improvements while maintaining operational stability.

Production Team Development

The foundation of manufacturing excellence is a skilled, engaged production team. My approach to team development focuses on providing comprehensive training, clear performance expectations, and regular feedback. I implement structured skills development programs that build technical capabilities while fostering problem-solving skills and continuous improvement mindsets.

This investment in people has consistently delivered exceptional results, including maintaining 0% turnover during significant operational changes at Chromalox and successfully managing workforce growth from 300 to 600 employees during Faurecia's plant expansion.

Manufacturing Experience

Plant management and production expertise across diverse industries

2020 - Present

Renewable Energy Manufacturing

Opal Fuels

As VP of Operations, I oversee manufacturing operations for multiple renewable natural gas facilities that convert waste into clean energy. Key manufacturing responsibilities include:

  • Managing production processes for renewable natural gas generation
  • Optimizing biogas collection, purification, and compression systems
  • Implementing preventive maintenance programs to maximize equipment uptime
  • Ensuring compliance with environmental regulations and safety standards
  • Coordinating production planning across multiple facilities

This role demonstrates my manufacturing expertise in continuous process operations within the renewable energy sector, with particular focus on sustainable production practices.

2017 - 2020

Industrial Heating Manufacturing

Chromalox

As General Manager at Chromalox, I led manufacturing operations for industrial heating solutions. My plant management achievements included:

  • Increasing manufacturing output by 34% through process optimization
  • Implementing cellular manufacturing concepts to improve production flow
  • Redesigning plant layout to optimize material movement and reduce waste
  • Establishing visual management systems to improve production visibility
  • Leading successful $58M facility expansion project in Ogden, Utah

This experience showcases my manufacturing expertise in discrete manufacturing environments, with emphasis on lean manufacturing implementation and production efficiency improvement.

2014 - 2017

Automotive Component Manufacturing

Faurecia

As Plant Manager at Faurecia, I led manufacturing operations for automotive components. Key manufacturing responsibilities included:

  • Managing high-volume production of automotive interior components
  • Implementing just-in-time manufacturing systems for automotive supply chain
  • Leading plant expansion that doubled production capacity
  • Reducing manufacturing waste by 22% through lean initiatives
  • Maintaining automotive quality standards (IATF 16949) across operations

This role demonstrates my manufacturing expertise in high-volume, precision manufacturing environments with strict quality requirements and just-in-time delivery expectations.

2011 - 2014

Bioethanol Production

Abengoa Bioenergia

As Operations Director at Abengoa Bioenergia, I managed manufacturing operations for bioethanol production facilities. Key manufacturing responsibilities included:

  • Overseeing continuous process operations for bioethanol production
  • Optimizing fermentation and distillation processes
  • Implementing efficiency improvements that increased yield by 15%
  • Managing raw material procurement and inventory control
  • Ensuring compliance with biofuel production regulations

This experience demonstrates my manufacturing expertise in process manufacturing environments, particularly in the renewable energy and biofuel sectors.

Manufacturing Technical Skills

Specialized expertise in manufacturing operations

Production Planning & Control

Developing and implementing effective production scheduling systems, capacity planning methodologies, and inventory management strategies to optimize manufacturing operations.

Manufacturing Metrics & KPIs

Establishing comprehensive manufacturing performance measurement systems including OEE (Overall Equipment Effectiveness), cycle time, throughput, quality metrics, and cost performance indicators.

Lean Manufacturing

Implementing lean manufacturing principles including 5S, value stream mapping, standard work, kanban systems, quick changeover (SMED), and continuous flow production to eliminate waste.

Quality Management Systems

Developing and maintaining ISO 9001 quality management systems, implementing statistical process control (SPC), and establishing robust quality assurance protocols for manufacturing operations.

Maintenance Management

Implementing preventive and predictive maintenance programs, total productive maintenance (TPM) methodologies, and reliability-centered maintenance approaches to maximize equipment uptime.

Manufacturing Technology

Evaluating and implementing manufacturing execution systems (MES), production monitoring technologies, automation solutions, and Industry 4.0 concepts to enhance manufacturing operations.

Manufacturing Case Studies

Real-world examples of manufacturing excellence

Production Output Increase at Chromalox

Challenge

The Chromalox manufacturing facility was operating significantly below capacity with production bottlenecks, inefficient workflows, and quality issues limiting output.

Approach

  • Conducted comprehensive value stream mapping to identify bottlenecks
  • Implemented cellular manufacturing concepts to improve production flow
  • Established visual management systems to improve production visibility
  • Developed standardized work procedures to ensure consistent quality
  • Implemented daily management systems with clear performance metrics

Results

  • 34% increase in manufacturing output
  • 0% employee turnover during the transformation
  • Significant reduction in production lead times
  • Improved on-time delivery performance
  • Enhanced product quality and customer satisfaction

Plant Expansion at Faurecia

Challenge

Faurecia needed to double production capacity to meet growing customer demand while maintaining quality standards and operational efficiency during the expansion.

Approach

  • Developed comprehensive expansion plan with phased implementation
  • Designed optimal plant layout to maximize space utilization and workflow
  • Implemented structured onboarding and training for new employees
  • Established robust quality control systems for new production lines
  • Created detailed transition plan to minimize disruption to existing operations

Results

  • Successfully doubled production capacity
  • Managed workforce growth from 300 to 600 employees
  • Maintained quality standards throughout expansion
  • Implemented lean manufacturing principles that reduced waste by 22%
  • Achieved on-time completion of expansion project

Yield Improvement at Abengoa Bioenergia

Challenge

The bioethanol production facility was experiencing below-target conversion yields, resulting in higher production costs and reduced output capacity.

Approach

  • Conducted detailed process analysis to identify yield loss points
  • Implemented statistical process control for critical process parameters
  • Optimized fermentation and distillation processes
  • Enhanced operator training on process control techniques
  • Established real-time monitoring systems for key process variables

Results

  • 15% increase in bioethanol production yield
  • Significant reduction in raw material consumption
  • Improved process stability and consistency
  • Reduced energy consumption per unit of production
  • Enhanced profitability through efficiency improvements

Looking for Manufacturing Expertise?

With over 20 years of experience as a plant manager and manufacturing operations executive across diverse industries, I bring proven expertise to optimize production operations and drive manufacturing excellence.

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