PATRICK L.

CAFFREY, PE, MBA

P.O. Box 189
Laughlintown, Pa. 15655
Home: 724/238-2242 – Cell: 724/396-0243 – Email: plcaffrey@verizon.net

Summary

I am a senior level operations professional who has provided the Leadership to

improve organizational efficiencies in a diverse mix of Industries and
organizations. A career spent developing and implementing strategies to improve
customer service, Quality and cost performance while delivering bottom-line
results. These were achieved utilizing modern Management techniques such as
Lean, Six Sigma and various team-based programs.

EDUCATION & LICENSES

Degrees: MBA – Point Park College; BS in Mechanical Engineering – Bucknell University
License: Professional Engineers License - 1985
Continuing Education: Levinson Institute on Leadership; Juran on Quality; various financial
management and sales courses

Selected Career Highlights

Engineered a 10% reduction in the workforce through change in methods and process while
improving Quality levels (application of Lean techniques). – MIC Industries
Reduced production man-hrs by 20% while maintaining production levels at a DOD supplier. –
MIC Industries
Achieved 5% Workers Compensation Premium reduction through Safety committee
certification and four years operation without an LTA. – MIC Industries
Improved Rev/Man-Hr by 20% and improved customer service by reducing past due deliveries
from 2 months to less than 1week at a DOD Manufacturer of electronic cabinets. – GKI
Developed and implemented the strategies to reorganize a unionized manufacturing facility
that was an asset purchase from a bankruptcy filing. The Company broke even in 6 months
and achieved profitability with $27 million in sales in 2 years as a result of my efforts. The
company posted consecutive periods of profitability that had not been achieved in the
previous 15 years. Edgewater Steel Ltd.
Developed and implemented strategies for expansion into Mexican and South American
markets and pursued a European alliance to increase international market penetration in
railway and bearing supply Industries. Edgewater Steel Ltd.
Operational strategies that significantly contributed to 40% improvement in volume, 15% cost
savings and a scrap rate less than 1%. Standard Steel Latrobe
Formulated and implemented utility brokering programs and monitoring systems to signifi-
cantly and consistently reduce utility costs. This created $1.7 million savings through the
implementation of a new natural gas brokering program. Standard Steel Burnham
Implemented a real-time utilities monitoring system that reduced the natural gas transmission
rate by 33% and reducing overall electric costs by 10% ($200,000 annually). Johnstown Corp.
Designed and implemented effective multi-craft maintenance program that consolidated 8
craft designations and yielded $1 million in annual savings. Standard Steel Burnham

1 PL Caffrey PE, MBA 724-238-2242

 Designed and implemented a cross-craft training program that was the basis of a pay for skill
system in a USW facility. Standard Steel Burnham
Successfully worked with unions to eliminate a steam plant with the reduction 6 employees
and an annual savings of $250,000. Edgewater Steel Ltd.
Revamped the IT system and installed a modern MRP and CMMS program. Also revised the
Product Engineering to a 3-D PRO-E software system. – Edgewater Steel Ltd.
Completed 16 week Juran on Quality Course. (Dr. Juran provided the direction for the Toyota
Production system and his program was the predecessor for the Six Sigma Programs and
Lean Manufacturing Initiatives currently being implemented.) – Standard Steel

PROFESSIONAL EXPERIENCE

MIC Industries – Elton, PA (2004 to Dec. 2009).

Plant Manager – Multi-Plant locations

Company manufactures patented machines for fabricating freestanding metal buildings for sale to DOD and
Foreign Governments.
 Responsible for spearheading operational efficiency improvements by compressing the
manufacturing cycle to double production.
 Reduced man-hours by 20% while maintaining previous production volume.
 Achieved 5% Workers Compensation reduction by certifying Safety Committee
Burley’s Rink Supply Johnstown, PA (2002-2004).
Consultant
Company fabricates and installs ice rinks internationally.
 Assisted owners of a $ 9 million family business in strategic planning, investor attraction and
aggressive cash management.
 Efforts improved contribution margin by 20%.
 Developed Business Plan and Private Placement Memorandum to reorganize the Business
through acquisition or merger. Emphasis on International expansion.
General Kinetics, Inc. – Johnstown, PA (2001-2002).
General Manager
Company fabricated electronic cabinets for DOD applications (primarily Navy). As both prime and Sub-contractor.
 Responsible for operational P/L for this $10 million, 90 employee unionized corporation.
 Efforts turned around past due deliveries to less than 1 week, reduced overall accident fre-
quency and severity by 80% and improved revenue/man-hour by 20%.
 Develop metrics for facility to measure performance against goals.

Edgewater Steel Ltd. (a Reserve Group Company) Oakmont, PA

President/CEO 1997-2000

A $27 mil. Forging facility manufacturing wheels and forgings for the transit and railway industries and seamless
rolled rings for the bearing industry.
 P/L responsibility for this $27 million, 180 employees unionized facility.
 Directed restructuring efforts to turn around the company from a history of bankruptcy into a $27
million business with 5% profitability in 2 years.
 Formulated and oversaw a $3.5 million capital investment program.
 Led initiatives to rebuild trust in the marketplace and within the plants, including resolution of
nd
bankruptcy legacy issues transforming a dispute the company’s 2 largest client; client
emerged with a rebuilt trusting relationship that resulted in a mutually agreeable strategy to
make the client whole subsequent to Edgewater’s prior bankruptcy.
 Board of Directors – Forged Products Ltd., Houston, Texas (affiliated Reserve Group Co.)

2 PL Caffrey PE, MBA 724-238-2242

Acutus-Gladwin Corporation East Pittsburgh, PA
General Manager 1996-1997

Continuous caster segment repair facility for USX-Mon Valley Works.

 P/L responsibility for a $5.5 million, 50 employees unionized business and equity participant.
 Developed a strategy to double volume, improve EBIT and achieve a revenue goal of
$150,000/employee; implementation required extensive involvement in rebuilding workforce
trust in order to resolve previously unsettled labor disputes.

PROFESSIONAL EXPERIENCE (continued)

Johnstown Corporation Johnstown, PA

Senior Manager 1993-1996
A $40 mil. Foundry operation producing large commercial castings and steel and iron rolls. Reported directly to
Chief Operating Officer with managerial responsibility for 5 staff and 55 union workers.
 Actively involved in the formulation and implementation of strategy, including capital planning,
environmental affairs and facility optimization.
 Developed operational strategies that reduced annual electricity costs by $200,000 (1month
payback) and achieved overall annual cost savings and avoidance of over $500,000.

Standard Steel (a division of Freedom Forge Corporation) 1976-1993

A $150 mil. Forging Company with Melting, extensive machining and heat-treating operations serving Railway
Supply, Aerospace and Capital Goods Markets. Producing large seamless rolled rings, forged railroad wheels,
railroad axles, Open Die and Closed Die Forgings.
Plant Manager – Latrobe Plant (1991-1993)
 As senior executive of the plant, reported directly to Vice President of Operations; workforce
consisted of 20 exempt and 150 union employees who produced $21 million in annual
shipments.
 Prepared and controlled a $16 million operating budget that consistently increased contribution
margins with below budgeted fixed costs. Covered $2.4 mil plant unfunded pension contribution
annually.
 Enhanced open-die forging market penetration by 20%.
 Successfully planned and led operations to increase volume (40%) reduce costs (15%) and
achieved low scrap rate (less than 1%).
Manager of Maintenance – Burnham Plant (1986-1991)
 Reported directly to Vice President of Operations; workforce was comprised of 22 exempt and
225 USW workers, as well as 3 exempt and 25 USW workers in Internal Transportation.
 In overseeing a $13 million budget, reorganized operations to achieve $1 million in annual
savings by creating a multi-craft maintenance program to reduce man-hours as well as save
$1.7 million annually through a new natural gas brokering program.
 Transformed the Maintenance Management function within the plant.
 Developed and installed of LAN for CMM System Novell system with HP hardware
 Implemented reductions in force that affected 75% of exempt and 70% of nonexempt workers.
Unit Manager – Area Maintenance (1983-1986)
 Focused primarily on reorganization and cost containment following an organizational
restructuring;
Superintendent – Melt Shop Maintenance (1979-1983)

Allegheny Ludlum Steel Company (affiliate of Standard Steel) Brackenridge, PA

Mechanical Engineer – Maintenance Department 1976-1979
Promoted to Burnham plant as superintendent of melt shop maintenance.

3 PL Caffrey PE, MBA 724-238-2242

U.S. Gypsum Company Oakmont, PA
Project Engineer – Environmental & Capital Installations 1974-1976

PROFESSIONAL ORGANIZATIONS & VOLUNTEER ACTIVITIES

Subject matter expert in the field of Leadership; published articles in magazine (Performance and Instruction)
and contributed articles to Marshall Institute seminar for Multi-Craft Maintenance.
Accomplished speaker having presented to professional societies, school and civic groups.
Past Chairman of the Central Pennsylvania Chapter of the American Society of Mechanical Engineers (ASME);
organized and moderated a full day DOE-subsidized Energy Seminar at Bucknell University.
Served on the Executive Board of the Boy Scout Council for Central Pennsylvania; directed launch and
expansion of Explorer program (an initiative for older urban adolescents) into 12-14 area groups; former Eagle
Scout.
Served as Secretary of the Burnham Borough Sewer Authority; approved $3.5mil Bond Issue to expand the
plant, provide 100% coverage in the borough and eliminate hydraulic overload situation of non-compliance.
Extensive involvement in adult and student soccer leagues; organized and arranged funding for a new soccer
program at Ligonier High School; organized and served on the Board of Directors of the Mifflin County Soccer
Club; coached youth soccer programs for 14 years. Currently playing in a Men’s league.
Church Finance Council Chair for the last 15 years. Led the Church from a $250,000 deficit to no debt,
established endowments and balanced budgets for both church and affiliated School.
Mentor for University of Pittsburgh School for Entrepreneurial Excellence

4 PL Caffrey PE, MBA 724-238-2242