OBJECTIVE: Department manager in a metals processing industry.
SKILLS: 30 years of engineering experience. Proven project management, supervision and leadership skills. Excellent people skills in a production and quality environment. Good communication skills; both written and spoken. Proven computer skills. Six Sigma Green Belt certified.
EXPERIENCE:
TMK-IPSCO Ambridge, PA Seamless Mill Manager 8/11 to 6/12
Department Manager responsible for long-term improvements to operations including:
• Reduction of quality rejects primarily due to Slivers in the Inside Diameter of finished tubes. Primary focus is to increase graphite lubrication on mandrel mill bars to reduce friction as tube lengthens on mandrel mill bar during the rolling operation.
• Managed the capital improvements in the hot mill department including the installation of new Piercer Outlet Stands and the Installation of Pure Oxygen burners in the Rotary Hearth Furnace to increase furnace throughput.
AK Steel Butler, PA Section Manager, Hot Mill Operations 6/10 to 8/11
Manager of Hot Mill Operations responsible for hot rolling electrical and stainless steels. Managed production and quality personnel to meet production and quality objectives. Managed department of fifty union employees. Additional responsibilities included:
• Led team to reduce holes in electrical steels. Reduced bottom holes by improving furnace maintenance. Another reduction was achieved by reducing the gauge off the hot mill (corresponding reduction in the amount of cold reduction).
• Improved magnetic properties of electrical steels by tightening process controls.
Hussey Copper, LTD Leetsdale, PA 15056 Manager, Melting and Casting 9/07 to 6/10
The Casting department uses a large 545,000 pound natural-gas fired reverbatory furnace for melting high copper percentage alloys and three electric induction furnaces for melting copper based specialty alloys. Specialty alloys include cupro-nickels, and other alloys containing aluminum, iron, magnesium, manganese, phosphorus, silver, and / or tin. Responsible for casting operations. Managed four supervisors and about 50 hourly employees.
During this period there was a significant reduction in laminations (holes in the metal downstream or entrapped slag) in 110 alloy (highest volume 99.9% copper) from 4% to 1%. Successfully developed casting procedures for 155 alloy (copper, silver, phosphorus, and magnesium) and 613/614 alloy (precipitation hardenable alloy containing copper, aluminum, iron, and tin).
Luvata, Buffalo Senior Process Engineer 9/99 to 9/07
Reroll Process Engineer 5/04 to 9/07
The Reroll department heats copper based slabs in a furnace to hot rolling temperatures. These slabs are hot rolled and upcoiled into coils. The milling line removes oxides on four sides of the coils. An optional in-line roll with the milling line makes up to a 50% reduction in the coils before upcoiling a tight-wound coil. A four-stand tandem mill rolls these coils between 0.28” and 0.020”. Quality and operating procedures for these operations are primary focus. Fill in as Reroll Supervisor and on some weekends act as 2nd shift Operations Manager responsible for all plant operations.
• Reduced product costs by minimizing gauges off the 4 stand tandem mill using all five of the rolls in the Reroll department. Eliminated downstream rolling operations.
Process Control Department 1/03 to 5/04
Process information is being transmitted through CITRIX servers to an Oracle database to monitor key process variables such as temperature, pressure, speed, flow, etc. Metallurgical Engineer who used this information to improve process controls.
• Reduced the number of hot roll passes on many copper alloys to increase production rates and improve product quality.
• Reduced casting variability by establishing target downcast speeds of each alloy and cast width.
Metallurgical Department 9/99 to 1/03
• Optimized hot rolling furnace soak times and temperatures. Improved plant yields. Yields in copper-tin and copper-nickel-silicon alloys were significantly improved.
• Controlled the raw material inputs into high tin bearing phosphorus bronze alloys. Improved hot roll yields.
• Eliminated a dirty strip defect in two copper-tin alloys by adding sulfuric acid cleaning.
• The solubility of most copper alloying elements (zinc, tin, phosphorus) increases with decreasing temperature. Led team to create a computer program to soak many of the alloys at a lower temperature then slowly ramp the temperature to a final temperature. Minimized temperature distributions within slabs, improved product quality, and reduced variability.
• Managed a project to reduce hydrogen in copper-nickel-silicon alloys. Changed the material used as a furnace cover from charcoal (source of water) to graphite pellets and powder. Implemented a minimum requirement of 20% raw material input into each batch. Began bubbling argon gas through the bottom of the furnace. As the hydrogen concentration decreased, the blisters were eliminated.
West Valley Nuclear Services; West Valley, NY (A subsidiary of Westinghouse) 4/87 to 9/99
West Valley was a spent commercial nuclear fuel reprocessing plant. West Valley beca...
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