Al Gibson Email & Phone Number

Saint Paul, Mn, Us

Minnetonka, Minnesota, United States

Packaging/Pleated Filters Supervisor

Gary, Indiana, United States

- Proficient in Updated Q-BOP Failure Mode and Effects Analysis (FMEA) for proactive identification and resolution of potential failures.- Applied Lean methodologies and best practices to optimize the melting process, resulting in increased reliability, waste reduction, and enhanced efficiency.- Utilized 5 Why analysis to identify root causes and executed corrective measures to mitigate recurring issues.- Led weekly GEMBA walks to drive continuous improvement and identify areas for quality enhancement.- Reviewed, updated, and communicated Standard Operating Procedures (SOPs), Job Qualification Requirements (JQRs), and Safe Job Procedures (SJPs) to ensure compliance and mitigate safety risks in an ISO 45001-certified plant.- Leveraged Oracle CMMS for efficient maintenance work requests, order management, and inventory optimization.- Implemented effective delegation strategies to empower team members, optimize work distribution, and boost overall productivity- Conducted regular communication meetings to facilitate feedback and foster knowledge sharing among team members.- Provided training and mentoring to new managers, equipping them with essential skills in Q-BOP systems, Lean techniques, conflict management, emotional intelligence, and process optimization.- Cultivated a culture of open communication, empowering employees to give and receive constructive feedback, contributing to their professional growth.- Successfully implemented SMART goal-setting techniques to align individual and team objectives with company goals, enabling effective measurement and continuous improvement.

Gary, Indiana, United States

- Full management accountability for all steel desulfurization, skimming and melting processes in the Steel Producing QBOP (quell basic oxygen process), along with environmental management systems in an ISO 14001-certified steel plant. - Plan and coordinate all operations across two shifts in producing 100+ grades of liquid steel with metallurgical properties customized to customer specifications, converting iron into ~13,500 tons of liquid steel daily. - Lead a 72-member team (indirectly supervising 60 maintenance techs, laborers and contractors) working the QBOP charge floor, furnaces, skimmer, charge cranes, gas cleaner, mixer, highline, scrapyard, desulfurization, charge and alloy aisles, and flux station.- Oversee quality assurance and best practices to ensure that products meet/exceed the company’s shop yield, melt order and supergrade standards, along with EPA and IDEM (state) requirements.- Prepare schedules for union workers and shift managers, along with manpower and equipment (cranes, lifts, etc.) for mixer outages, furnace pit cleaning and skimmer outages.- Manage the reliable, effective operation of environmental management systems, such as dampers, fans, clean water pumps, roof monitors, gas cleaners, furnace hoods and the baghouse.- Coordinate all QBOP safety and hazard management programs, including audits, incident investigations and projects to eliminate hazards and mitigate safety risks.- Direct employee training and mentoring in team communication and problem-solving, conflict management, 5S/5-Why/lean methods, waste reduction, environmental policies, etc.- Spearhead investigations into quality issues via 5-Why analysis, raw material/product evaluation, product batch record reviews, NMRs, compliance audits and instrument calibrations.- Lead biweekly safety meetings, daily safety huddles, gemba walks, ongoing review and revisions to SOPs, safe job procedures and job qualification requirements.

Gary, Indiana, United States

- Accountable for planning and coordinating the flow of production materials and labor to meet goals for efficiency, quality and volume. - Oversaw steel melter chemistry, temperature, safety and maintenance to facilitate on-time production within quality specifications. - Leveraged extensive steelmaking expertise and lean manufacturing methodology to establish SOPs that shortened processes, boosted efficiency, increased safety and improved quality. - Recognized for high levels of plant safety and cleanliness with very few recordable or lost-time incidents.- Investigated and addressed environmental alerts and safety incidents, working closely with shift managers to initiate action plans and ensure compliance with EPA and IDEM standards.- Coordinated lean manufacturing programs to reduce production waste and associated costs; also implemented ISO 14001 quality and sustainability standards.- Performed quality investigations and advised operators of the parameters to meet specifications (alloy hardness, toughness, yield strength, corrosion resistance, plasticity and malleability).- Facilitated a lean and diverse workforce with rapid operational mastery by cross-training operators with a strong technical foundation.- Partnered with senior management to develop and implement strategies to improve safety, chemistry, maintenance and production efficiency.

Gary, Indiana, United States

Steel Producing QBOP Charge Floor

Gary, Indiana, United States

Steel Producing QBOP Charge Floor

Gary, Indiana, United States

Steel Producing QBOP

Gary, Indiana, United States

South Blast Furnace Stockhouse, Highline, Blast Furnace Casthouses #4, #6 & #8, Gas Washers, Dustcatchers

Gary, Indiana, United States

39D Deskulling Platform & Iron Beaching Facility, Iron Producing Tar Station, Bulk Oil Facility

Gary, Indiana, United States

Conducted physical and chemical quality assurance examinations of hot roll products.