PROFESSIONAL SUMMARY
Chemical Engineer with over 14 years of manufacturing experience in a continuous chemical processing environment. Strong record in initiating continuous improvement and cost savings projects, particularly in the area of energy reduction. Experienced in process design and plant automation, including involvement in the building of a green-field chemical plant in Guanxi, China. Skilled in communicating with a diverse group of employees, both on a domestic and an international level.
Professional Strengths:
♦Continuous Improvement ♦Project Management ♦Customer Interaction
♦Energy Savings ♦Process Design and Automation ♦Employee Development
• Continuous Improvement Training as both a Lean Facilitator and Six Sigma Industrial Black Belt
• Configuration and programming of the plant’s Distributive Control System (DCS) and controls tuning experience
• Design, equipment selection, and operational support for a Greenfield EMD plant in China
• Management of hourly / salary reports in a union environment, including interviewing and hiring processes. Collective bargaining and grievance experience
• Both capital project and process engineering experience
• Design, production, and commercialization of two new products representing 10% of total production in 2010
• Customer interaction for analysis of process capability, continuous improvement programs, and sales opportunities.
• Energy Team reduced plant natural gas usage by 41% and electricity consumption by 11% per ton produced
• Yield Team improved ore conversion rate from 83% to 92%.
• Training includes 24-Hr Hazmat Tech., First Responder, Confined Space Non-entry Rescue, Drug Awareness, and Media Relations Training.
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Erachem Comilog Inc. (formerly Chemetals), New Johnsonville, TN
Engineering Manager, Production Manager, Manager of Process Eng / Quality Assurance / Environmental Compliance, Process Eng II, Process Eng I / System Coordinator 10/98 – present
Erachem Comilog, Inc. is a subsidiary of Eramet, a French corporation working predominately in the metals and mining industries. The New Johnsonville plant consumes Manganese Ore from our parent company to produce Electrolytic Manganese Dioxide (EMD) for the Alkaline Battery Industry. This is a continuous chemical process, operating both 12 hour rotating and eight hour shifts with a budgeted Rectifier on-stream time of 99%. This is accomplished through high levels of plant automation. I have held various positions within the organization, as detailed below.
Engineering Manager 10/10-present
This Staff Level position includes responsibility for the Capital Program ($2.5M-$3.5M/yr), the Continuous Improvement Program, the plant Process Engineering, and the Distributive Control System (DCS). Three experienced engineers and a Continuous Improvement Facilitator support me in this role.
The primary duties of this newly created staff level position include:
• Helped institute the new contractor safety program in 2012, while qualifying several new contractors for the site.
• Development and oversight of the plant’s continuous improvement efforts, including the creation of the Continuous Improvement Steering Committee. The primary goal of the committee is to make sure that the goals and accomplishments of the CPI program are understood at all levels of the organization. The goals set were measurable and published utilizing Overall Equipment Efficiency (OEE) for key process areas.
• Document the savings achievement of the department to ensure that the goals of the group are achieved. This involves verifying improvements are sustainable and maintained going forward.
• Scheduling and documenting safety reviews for existing processes and new installations. Coordinate start-ups of new process equipment.
• Assigned a temporary position as Project Manager leading the NJV 4,250Metric Ton Expansion Project in Nov 2011. This $13.4M project allows for the use of a lower grade ore while increasing the plant’s overall capacity by 17%. This was performed in conjunction with the $2.5M plant capital plan and $1.3M in Storm Damage repair in 2012. Expansion completion scheduled for April 2013.
Production Manager 6/06 – 9/10
The primary duties of this staff level position included:
• Ensure that processes were operated efficiently to meet all environmental, safety, and process guidelines.
• Direct supervision of 8 salaried supervisors and indirect supervision of 46 hourly employees in a union environment. This included involvement in the grievance, arbitration, and Collective Bargaining processes.
• Manage an Operating Supplies Budget of $1.5M/yr, as well as inventory of reagents to ensure stable operations.
• Work in conjunction with the corporate EMD Sales Manager to manage inventories of finished goods, as well as product performance to meet expectation of all three US battery producers.
• Led development and production of two new products in conjunction with the ECI Sales and Technology groups. Z100 was developed for the high performance AA / AAA applications, allowing the plant to compete successfully in this area for the first time in many years. Sales in 2010 including 10% of our total production, growing to 15% in 2012. CMD was a new product for the pigment industry, allowing for the sale of off-grade that previously required rework.
• Work in conjunction with the Maintenance Manager to coordinate maintenance activities while achieving 99%
Cell Room Rectifier On-stream.
• Provide Support via teleconferences and on-site visits for the Chinese EMD facility conversion to a continuous process. Coordinate trips to New Johnsonville for the training of key China personnel.
Manager of Process Technology / Quality Assurance / Environmental Compliance: 4/05 – 5/06
The primary duties of this staff level position included:
• Direct supervision of 8 salaried employees (6 degreed professionals) and one Contract Engineer.
• Manage the Information Systems Supervisor with responsibility for the DCS and Plant Information Systems.
• Manage the Plant Quality Programs, as well as the Quality Assurance Laboratory. Responsible for final Certificate of Analysis for shipments and analysis of Process Capability for key product specifications.
• Lead the plant’s continuous improvement activities and process engineers. Emphasis was placed on the success of the plants Energy Improvement Team.
• Was the plant’s main contact for process design of the China Project, a green-field EMD project in the Guanxi Province. This included PID development and ...
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