FRANK CAROTO
Cork
Summary
Results-driven production and operations executive with more than 20 years of leadership in multi-line manufacturing across various industries, including aviation and biopharmaceuticals. Track record of achieving measurable improvements in efficiency, quality, and safety while managing complex production environments. Strong background in lean manufacturing and continuous improvement practices, focusing on waste reduction and process optimization. Experienced in collaborating with quality and supply chain teams to execute production plans and ensure compliance with industry standards.
Overview
33
33
years of professional experience
Work History
DC Operations Manager
ABEC Biopharmaceutical Manufacturing
Cork, Ireland
04.2025 - 10.2025
- Oversaw end-to-end operations across shifts, managing staffing, training, performance reviews, and safety compliance to ensure operational continuity.
- Led two production teams, comprising one team lead and 10 technicians, ensuring safety and efficiency in operations.
- Implemented process optimizations and established performance metrics to enhance continuous improvement initiatives.
- Collaborated with quality, scheduling, and engineering teams to meet production objectives and uphold quality standards.
Senior Production Supervisor
Wisetek
Cork, Ireland
04.2023 - 03.2025
- Achieved a 10% increase in production performance within three months through strategic improvements.
- Optimized labor efficiency by managing attendance and overtime allocation effectively.
- Directed 73 employees across eight departments, collaborating with 11 team leaders to streamline operations.
- Orchestrated daily production meetings with team leaders and technical stakeholders, enhancing communication to improve output.
- Generated and disseminated KPI summaries to track performance against targets and inform strategic decisions.
Senior Production Manager
Farran
Cork, Ireland
01.2022 - 03.2023
- Ensured finished goods met quality standards and adhered to manufacturing instructions, contributing to customer satisfaction.
- Provided technical advice on design specifications for new products, enhancing product quality and compliance.
- Planned resources and monitored output to maintain schedule adherence and delivery performance.
- Collaborated with senior leadership to align objectives and execute operational plans.
- Enforced health and safety standards, supported budgeting activities, and implemented lean/6S initiatives to improve operational efficiency.
- Conducted performance reviews and coached production personnel to enhance capability and accountability.
Independent Production Consultant
Lisbon, Portugal
02.2021 - 12.2021
- Advised on production setup and process flow optimization, implementing lean strategies to streamline operations.
- Conducted efficiency and quality reviews to enhance production line layouts and improve workforce training outcomes.
- Delivered consulting and contract support for small to mid-scale manufacturing clients across Portugal, improving operational effectiveness.
Head of Production
LED Lighting SA
Cape Town, South Africa
01.2020 - 01.2021
- Successfully led multi-shift operations, achieving a 45% increase in output and a 15% reduction in labor costs.
- Re-engineered production flow, relocating 150 machines to enhance on-time delivery by 45%.
- Managed team of over 50 across four production lines, achieving demanding KPIs.
- Implemented lean methodologies, Six Sigma, and Kaizen, enhancing cost efficiency.
- Reduced inventory value from R20 million to R14 million within five months, improving order arrears by 65%.
Head of Production
Zyteq Technologies
Cape Town, South Africa
12.2013 - 12.2019
- Planned and constructed factory from inception, achieving ISO certification in 2014.
- Led team of over 20 in manufacturing PCB placements across two production lines, including quality assurance testing.
- Managed SMT line equipment, ensuring optimal functionality of stencil printers, conveyors, SMT machines, reflow ovens, AOI, wave solder, and selective coating.
- Enhanced machine readiness and adoption by creating guidance manuals and training operators on new equipment.
- Expanded local and international client base by developing innovative products and executing timely deliveries.
Senior Production Manager (Contract)
MacNeil Plastics
Cape Town, South Africa
12.2012 - 11.2013
- Achieved record KPIs within six months: +5% efficiency, +4% productivity, and +8% sales.
- Implemented Lean Six Sigma 5S methodology, reducing labor costs by 10%.
- Led team of over 50 members, managing recruitment, training, and achievement of KPIs.
- Introduced policies that enhanced on-time delivery by 12% while improving product safety and quality.
- Established SQDCI targets across three production lines, enhancing operational performance.
- Supported budget quotations and client reporting processes, ensuring financial accuracy and transparency.
Head of Operations
RotorWay Helicopter Manufacturing Co.
01.2007 - 12.2012
- Directed 15+ direct reports across 10 production lines assembling non-commercial helicopters and reported operational metrics to CEO.
- Delivered projects increasing efficiency to 118% and productivity to 150% across production lines.
- Project managed a cost reduction programme cutting costs by 55% and increasing turnover by 50%.
- Reduced customer arrears by 68% and increased delivery schedule adherence by 30% in partnership with customer relations.
- Prepared production lines for ISO 9001 certification alignment.
SMT Production Manager
General Electric
02.1993 - 12.2006
- Managed 2 supervisors and over 100 employees across two large-scale production departments, ensuring operational efficiency and meeting production goals.
- Increased Overall Equipment Effectiveness (OEE) by 23% to 79%.
- Improved First Yield Pass during AOI from 24% to 94%.
- Embedded ISO 9001, IPC-A-610, and IPC-CC-830C standards, fostering quality assurance and compliance in production processes.
- Recruited, inducted, and trained SMT production teams across Connecticut and Massachusetts, enhancing team readiness for production demands.
Education
Degree - Production Management
Diploma - Electrical & Electronics Engineering
Certificate - Operations & Supply Chain Management
Certificate - FMCG for Management Consultants & Business Analysts
Certified - Six Sigma
Skills
- Production and manufacturing leadership
- Multi-shift operations
- Factory planning and startups
- Continuous improvement strategies
- KPI and SQDCI management
- OTIF, OEE, and yield enhancement
- Quality assurance processes
- Health and safety adherence
- Inventory, waste, and labor optimization
- Budgeting and forecasting
- Risk assessment and management
- Team leadership and development
- Stakeholder and client relations
- Budgeting and forecasting
Languages
English
Native
Native
Portuguese
Proficient (C2)
C2
Afrikaans
Proficient (C2)
C2
Timeline
DC Operations Manager - ABEC Biopharmaceutical Manufacturing
04.2025 - 10.2025
Senior Production Supervisor - Wisetek
04.2023 - 03.2025
Senior Production Manager - Farran
01.2022 - 03.2023
Independent Production Consultant -
02.2021 - 12.2021
Head of Production - LED Lighting SA
01.2020 - 01.2021
Head of Production - Zyteq Technologies
12.2013 - 12.2019
Senior Production Manager (Contract) - MacNeil Plastics
12.2012 - 11.2013
Head of Operations - RotorWay Helicopter Manufacturing Co.
01.2007 - 12.2012
SMT Production Manager - General Electric
02.1993 - 12.2006
Cape Peninsula University of Technology - Diploma, Electrical & Electronics Engineering
- Certificate, Operations & Supply Chain Management
- Certificate, FMCG for Management Consultants & Business Analysts
- Certified, Six Sigma
University of South Africa - Degree, Production Management