US Department of Justice / Federal Prison Industries, Inc.
Washington, DC
Chief Executive Office, Federal Prison Industries, Assistant Director,
Bureau of Prisons, US Department of Justice
At Federal Prison Industries (FPI), a distinctive self-sustaining manufacturing powerhouse within the Federal Government, Mr. O'Connor wields full P&L responsibility for seven diverse product and service groups: Agribusiness, Clothing and Textiles, Electronics, Fleet, Office Furniture, Recycling, and Services, with annual revenues exceeding $500 million. His role is pivotal, involving overseeing strategic planning and managing operations across over 75 factories in 54 federal prisons nationwide. Under his leadership, FPI supports approximately 11,000 employees daily and provides invaluable training to around 16,000 federal inmates each year. As a Senior Executive Service (SES) member, the highest rank in federal service is just below a Cabinet position. Mr. O'Connor reports directly to FPI's Presidentially appointed Board of Directors. His unwavering strategic vision and meticulous execution drive significant advancements in workforce training and operational efficiency, fostering a culture of accountability and collaboration. Through his stewardship, FPI continues to produce over 17,000 varied products and services, firmly maintaining its independence from taxpayer funding while playing a crucial role in the defense manufacturing sector.
- Expanded top-line revenue by 28.6% since FY19, driving $853 million in orders by FY20 and maintaining 7-10% profitability annually.
- Achieved a $23.6 million year-over-year profit increase between 2023 and 2024, overcoming high inflation and supply chain challenges.
- Led FPI’s COVID-19 pandemic pivot, producing PPE for DHS and DOD while maintaining essential services and employing over 17,600 inmate workers—35% ahead of target.
- Appointed to the Senior Executive Service (SES) in 2018, overseeing P&L for seven business segments with over $540 million in annual revenue.
- Transformed FPI’s technology infrastructure, implementing SAP S4/HANA ERP, Salesforce, and GovWin, earning a nomination for the FedScoop 50 Award in 2022.
- Opened 10 new factories since FY19, expanding FPI’s capabilities across 75 factories in 54 federal prisons nationwide.
- Maintained 100% compliance with federal audit standards throughout tenure, ensuring operational integrity and accountability.
- Restructured the organization by creating "Profit Centers" and "Cost Centers" with clear KPIs, driving efficiency and accountability.
- Forged an award-winning partnership with George Washington University, providing leadership coaching services to FPI employees and promoting continuous improvement.
- Adapted processes to counter supply chain disruptions, maintaining profitability and operational efficiency amid global challenges.
Readyone Industries INC.
El Paso, TX
Vice President, Business Development
Non-Profit dedicated to the employment of the severely disabled. Business segments include military / commercial garment manufacturing, call centers, document services, corrugated packaging & 3PL services.
- Business Process Development - Established business development group and implemented “Shipley” based proposal management process resulting in a 52%-win rate on proposals and $179.7 million in contracts won in 1st 11 months of 2016.
- Online Marketing - Designed & launched new on-line presences for 5 divisions and secured Goggle GrantPro status.
- Market Development - Developed opportunities pipeline in excess of $1.2 Billion.
- Secured 5-year M&D contact for development of US Army’s new UIPE2 chemical warfare uniform
- Launched commercial cut & sew operations servicing the fashion industry
- Captured Defense Logistics Agency contract for chemical protective uniforms to US Air Force, value $74.9 million.
- Diverse Customer Base - Customer base expanded to both Governmental customers such has GSA, US Postal & Defense Logistics Agency to include commercial automotive (Federal Mogul) & fashion such as Levi’s, Ralph Lauren and True Religion
Lockheed Martin Corporation
Baltimore, MD
Director, Strategy & Business Development
Dedicated to the rapid development and commercialization of nanotechnology.
Applied Nanostructured Solutions LLC, (a wholly owned Subsidiary)
- Commercialization - Developed product concepts, business and commercialization plans for new technologies.
- Product Insertion - Insertednano-enhanced composites & thermoplastics on US Army & Navy programs.
- Supply Chain - Secured major supply chain partners in thermoplastics & composite sectors in China & North America.
- Business Development - Developed relationships with premier customers including 3M, Apple, GM, Nike, Sabic, Samsung & TE Connectivity.
The Collins Group INC.
Montreal, Quebec, Canada
Executive Director
The Collins Group is an independent company providing customized services in investment banking, mergers, strategic partnering and business planning and support to corporate clients. We target cross-border and cross-Atlantic financing, Strategic Partnering, and M&A transactions from $3 to $250 million for our private and public clients in Asia, Europe, North & South America.
- Corporate Financing - Arranged financing for development, expansion, acquisitions and buy-outs.
- Advisory - Provided counsel and advisory services to private and public companies on financing and M&A assignments.
- Private Placements - Sourcing financing for our clients from US and European VCs and PEGs.
- Business / Technology Planning - Prepare business, technology development and market rollout plans.
- Mergers & Acquisitions - Support at all stages of the M&A process - strategy and target identification, evaluation, initiation, discussion and negotiations, and completion.
- Due Diligence - Prepare our clients for the investment due diligence process.
- Strategic Partnerships - Identify and recruit Strategic Partners for technology companies, and also arrange channel distribution and VAR agreements for them.
Canadian Start-UPS
Canada
Company produces high surface area nano-perovskite based catalysts targeted for the Emission Control market, primarily diesel application. Recruited by the preferred shareholders (VC) to re-launch the Company and prepare it for divestiture. Held full P&L responsibility.
Nanox, INC.
Quebec City, Quebec, Canada
Chief Executive Officer / Director General
Company produces high surface area nano-perovskite based catalysts targeted for the Emission Control market, primarily diesel application. Recruited by the preferred shareholders (VC) to re-launch the Company and prepare it for divestiture. Held full P&L responsibility.
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Business Development - Launched 2 new families of products aimed at reducing the amount of PGM (Platinum Group Metals) required to meet emission control standards.
- Secured product development contract with Caterpillar, a world leader in diesel engine design & manufacturing.
- Expanded product into the petro/chemical sector by developing custom formulations for UOP.
- Entered into products into vendor qualification at Daihatsu & Ford.
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Organizational Restructuring - Reorganized organization to allow for improved responsiveness to customer needs.
- Simplified order fulfillment process
- Developed and implemented companywide KPIs.
Nanometrix
Montreal, Quebec, Canada
Chief Executive Officer
Provided vision, direction and leadership to this start-up company that developed a breakthrough monolayer-based thin film technology that enables the next generation semiconductor and advanced materials sectors. Held full P&L responsibility.
- Corporate Financing & VC Relations - Secured $2.5 million in additional seed capital, built relationships and negotiated with VC firms for series "A" round financing, and negotiated loan guarantees to fund R&D activities.
- Sales & Marketing - Served as a one-man sales/marketing team focused on targeting the semiconductor, bio/pharma, and advanced material sectors. Spearheaded a guerrilla marketing program that ignited instant credibility and positioned the five-person company alongside major industry players, including GE Global Research, 3M, and Los Alamos National Laboratories.
- Technology Prototype - Brought a computerized prototype machine online and led successful effort to move the Mark IV prototype into operations, enabling samples to be made for firms (e.g., Intel, Samsung, and Merck).
- Joint R&D - Negotiated a joint development agreement with one of Europe's largest research institutes.
- Sales Funnel Development - Developed a sales funnel with 13 world class clients that represent seven countries and five sectors.
- International Awards - Led Nanometrix to several international awards, including the NSTI Award, Tokyo; and the SEMI Technology Innovation Showcase; company was also named to NASA Tech Briefs Nano 50 ("winners of the Nano 50 awards are the best of the best - the innovative people and technologies that will continue to move nanotechnology to key mainstream markets," Linda L. Bell, publisher of Nanotech Briefs).
Bragg Photonics
Montreal, Quebec, Canada
Chief Technical Officer / Vice President, Business Development
Scope of responsibility encompassed technical, production, manufacturing, engineering, R&D, purchasing, marketing, sales, MIS, staffing and business development functions at this start-up company focused on the design and development of component solutions for high speed fiber optic telecommunication networks. Managed 350 employees located at two facilities; full P&L accountability.
- Revenue & Market Share Growth - Grew revenues from $5 million to $150 million and increased market share from 10% to 45%, and outpaced competitors by driving forward quality, on-time delivery and technical assistance initiatives; company was recognized by Deloitte & Touché as a Tech "Fast 50" in Canada.
- Business Development & Partnerships - Penetrated and grew business with clients in the U.S. and Asia (Nortel, Lucent, JDS Uniphase, Corning, Agere) and built/managed a network of agents and representatives worldwide and relationships with University R&D partners in Canada, China, Germany, and Hong Kong.
- Product Development & Launch - Led the development of tunable optical filter technology (a product line with three distinct units for different performance requirements and price points) and generated two patent filings; also guided the development and launch of a tunable laser system for a U.S. major U.S. military contractor. Completed the product development cycle of the laser system within two months.
- Joint Venture & Start-up Subsidiaries - Structured and negotiated a JV agreement for the development of manufacturing facilities in Malaysia and drove the start-up of subsidiaries in Hong Kong, Singapore, and the People's Republic of China.
- Operations, Staffing & Hiring - Assigned top-caliber manufacturing personnel in key positions and revamped hiring practices for production positions.
- Manufacturing & Production - Built the operating infrastructure, introduced TQM and lean manufacturing techniques, and led cultural transition from a R&D focus to a production-driven business model.
Hoya Lens Of America
Bethel, CT
Vice President of Operations / Research & Development
Significantly contributed to positioning this optical products marketer/supplier as the second largest optical lab firm in the U.S. Recruited by the CEO to direct all aspects of operations for a start-up American Division that was formed to penetrate the U.S. market. Oversaw materials, production, facilities, MIS, maintenance, quality assurance, and customer service functions. Managed a 75-person cross-functional team; held full P&L responsibility.
- Start-up Leadership & Revenue Growth - Transitioned the American division from start-up / zero in revenues into a mature, 1500-employee operation generating $157 million in revenues within 13 months.
- Hiring & Training - Hired, trained, and managed sales/marketing, customer service and call center personnel, and coached the sales team by taking them on sales calls to demonstrate proper sales techniques.
- Marketing & Trade Shows - Collaborated with team to develop a new marketing plan and collateral materials, and continually attended and worked at trade shows.
- Acquisitions & Business Integration - Achieved tremendous growth by managing acquisition planning, analysis, due diligence and candidate review, and participating in negotiations for $157 million in acquisition deals that included 14 operating units. Championed Hoya's philosophies and technologies, and effectively merged leveraged and consolidated combined synergies and resources to ensure seamless integration.
- Technology Transfer - Traveled to Europe and Japan to coordinate and facilitate technology transfer.
- Liaison Affairs & Problem Resolution - Liaised with Japanese engineers and contractors, and intervened on and addressed/resolved problems with local building codes and permits; also negotiated with the EPA and resolved issues with Connecticut's environmental laws; company was the only optical laboratory to receive an environmental permit award by the State of Connecticut.
The Monsanto Company
Allentown, PA
Corporate Director of Manufacturing
Member of the management team and the Strategic Leadership Council at this $6 billion life sciences company. Facilitated Monsanto's entry into the optical market by providing expertise in strategic planning, manufacturing, marketing, and product development. Oversaw 226 cross-functional employees (materials, engineering, production, facilities, and maintenance and quality assurance). Managed a $50 million budget; full P&L responsibility.
- Strategic Planning & Global Team Building - Spearheaded strategy for all manufacturing operations worldwide (10,000 employees, NutraSweet, Searle, Beniva, Agricultural Products, Fibers), coordinated teams, and established a global network partnership to share best practices and foster a commitment to excellence.
- Facility Construction - Planned, budgeted, and managed the construction of a 117,000 sq. ft. high technology, semi-conductor grade vacuum coating plant facility with a 15,000 sq. ft. Class 100 clean room.
- Productivity & Quality - Improved productivity/quality by implementing SPC and other systems/technologies.
- Product Development - Led the development of an innovative new product that captured 50% market share in the test market within 90 days and drove estimated first-year revenue projection of $150 million.
- Hiring & Training - Hired, trained and managed sales/marketing and customer service staff, and accompanied sales staff on sales calls.
- Advertising & Trade Shows - Selected an advertising agency and oversaw the development of a television and print ad campaign, and continually participated in industry trade shows.
O'Connor Management
Seminole, FL
President
Launched a consulting practice specializing in new facility design, operations, process redesign, productivity improvement, and quality.
- Quality Management & Control - Led SPC, ISO 9000, and quality initiatives for U.S. Navy, Johnson & Johnson and others. Operated as a subcontractor Juran Institute doing quality work. Subcontracted market and technical research for McKinsey & Co. - major customer was Monsanto.
- Process Reengineering - Reduced lead time 28%, labor requirements 20% (within six months) and reduced back orders from 40% to less than 5% for a start-up graphic design fabricator by leading internal process reengineering to improve customer service. Served as the company's Interim COO.
- Profit Revitalization - Restored profitability to a FAA-certified repair station that was facing bankruptcy. Retained as President and recruited a new management team, drove new market entry, and built a network of market reps that drove business and relationships in the U.S., Europe, and China; also secured Europe Aviation Administration approval/certification by the Civil Aviation Authority of China.
Essilor International / Transitions Optical
St. Petersburg, FL
Operations Manager (VP Level) (1990 to 1992)
Production Superintendent (1987 to 1990)
Instrumental in taking this joint venture from a two-person start-up into a Fortune "Fast 500" $200 million manufacturer. Promoted to plan and manage operations for the Essilor side of the Transitions Optical joint venture with PPG. Hired, trained and led a sales/marketing staff and managed a 300 - person cross-functional team.
- Revenue Growth - Generated $20 million in first-year revenues (exceeding goal 33%) and drove revenue growth to $200 million by the second year.
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Marketing & Product Launch - Spearheaded a high-profile marketing and product launch for the introduction of the world's first photo chromic plastic lenses (Transition Lenses) and orchestrated other product launches.
- Rented Liberace's mansion in Las Vegas for a product launch campaign and bussed in "customers' customers" to introduce them to the television ad campaign that their customers would be viewing.
- Identified 1.5+ million defective units prior to a nationwide product launch; quickly formulated method for chemically reworking the product and hired temporary staff to fulfill implementation, resulting in cost-effective resolution (less than $.10 per unit) of defect while ensuring timely, on-schedule product release.
- Contract Negotiations - Structured and negotiated OEM agreements with American Optical, Vision-Ease, Orcolite, Sola International, and Younger Optics to accelerate distribution.
- Plant Facility Construction - Coordinated the construction of a state-of-the-art plant facility with mass production equipment for commercialization (completed the $40 million project on time and ahead of budget). Transitioned a pilot plant into a facility to support production/order fulfillment efforts during construction phases and delivered the first shipment 127 days of initial approval of building permits.
- Productivity Improvement & Cost Reduction - Strengthened productivity by introducing the practice of self-directed work teams and emphasizing employee empowerment, and reduced operating costs $1.1 million by initiating process improvements for scrap reduction and automated equipment installation.
Early Career
- Manufacturing Manager - Schering Plough Corporation, Chicago, IL (1984 - 1987)
- Supervisor - United States Steel, Gary, Indiana (1973 - 1984)
Professional Recognition
- Senior Fellow, Lehigh University Systems Enterprise Center – Bethlehem, PA (July 2024)
- NANO 50 Award, Inaugural NASA TechBriefs – Boston. MA (Nov 2005)
- Emerging NanoBusiness Showcase, SEMI NanoForum. Chicago, IL (Nov 2005)
- SEMICON West – Emerging Technology Showcase, July 2005
- NanoJapan 2005 - Tokyo (2005)
Selected Speaking Engagements
- National Correctional Industries Association, Minneapolis, MN (Apr 2019)
- National Association of Institutional Agribusiness, Lompoc, CA (Oct 2019)
- TechConnect World Innovation Conference, Subject: Nanocomposites: Processing & Applications
- Gaylord National Convention Center, Washington, DC, (May 2016)
- SPE ACCE, "Using Carbon Nanostructures to Fabricate Multifunctional Composites & Polymers", Novi, MI Sept. 2015
- Advancing Technology for Business, Lehigh University, May 2015
- SAMPE/CAMX – Manufacturing Process for Carbon Nanostructure Infused Surfaces to Fabricate Multifunctional Components. Orlando, FL (Oct 2014)
- 6th Annual Conference of the Innovation Alliance Carbon Nanotubes, University of Wurzburg, Karlsruhe, Germany. (Feb 2014)
- Carbon Fiber R&D Workshop, A New Approach to Carbon Fiber, Buffalo, NY, Jul 2013
- SEMICON West – Emerging Technology Showcase, San Francisco, CA (2005)
- European Nano Systems - ENS 2005, Paris, France (2005)
- Organic Semiconductor Conference, Cambridge, UK (2004)
Board Leadership
- QD SOLAR Advisory Board Member 2014 to 2016
Secured $20M-$30M funding to manufacture solar technologies by building partnership with Saudi University (KAUST).
- BEN FRANKLIN TECHNOLOGY PARTNERS Advisory Board Member 2002 to 2012
Leveraged global executive network to connect Nitto Denko Corp. with a seed-funded green laser diodes product.
