Carl Couch Email & Phone Number

North Charleston, SC

• Managed the operation and maintenance of three paper machines, roll finishing and shipping departments, generating 1400 tons ($1,000,000) of production during a 12-hour shift using 8D problem solving to meet and exceed.
• Led a team of 52 operators and 7 maintenance mechanics to safely maximize production efficiency and product quality in a Lean, results-oriented environment.
• Ensured all safety procedures were understood and followed in order to promote a safe and healthy work culture.
• Maintained vigilant communication and visibility with operators and maintenance personnel to facilitate immediate response to any issues that could impair operational excellence.
• Built a team culture that fostered personal initiative to reduce bottlenecks and improve product quality.
• Confirmed product quality inspections were performed and documented in accordance with specifications, procedures and best practices.

North Charleston, South Carolina

• Directed and supported the cross-functional, interdisciplinary team of maintenance supervisors, leading the short and long-term Operational Excellence efforts of the paper machine and Cartesian robotics roll finishing.
• Led the team in a daily process reliability review for the allocation of short and long-term resources to drive continuous improvement initiatives.
• Used predictive observations and time-based preventive maintenance to determine the scope, schedule and budget of projects affecting production efficiency.
• Developed standards and procedures and then conducted needed training.
• Captured Operational Excellence initiatives / corrective actions to track these projects to completion.
• Continually improved systems impacting safety, production, reliability and quality using the DMAIC cycle.

North Charleston, South Carolina

• Managed multiple, simultaneous aspects of 13 chemical systems, including material transportation, loading/unloading, delivery as well as material selection and equipment inspection.  Supervised a 180-ton process.
• Led equipment trials/design/selection/installation/startup and developed operating/ maintenance procedures and training for an innovative $9.6 million stock prep system that allowed for product differentiation, added.
• Led a team to develop a new process using the Lean techniques, administered lab and pilot plant trials, new equipment selection, installation and start up, wrote operation and maintenance procedures to allow $2000/day.
• Led in the design/installation/startup of a $4.3 million sodium hypochlorite system to replace elemental chlorine, allowing the decommissioning of the process safety management covered process.

North Charleston, South Carolina

• Led application of the DMAIC cycle to determine the root cause of repeat equipment failure and determine appropriate corrective action. Then, track the corrective action to completion.
• Used predictive observations and time-based preventive maintenance to determine the scope, schedule and budget of projects affecting production efficiency.
• Developed mill wide standards and procedures for equipment alignment and then conducted needed training.
• Conducted vibration analysis to determine equipment health and scheduled maintenance.
• Conducted equipment and lubricant inspections to determine equipment health and scheduled maintenance
• Performed equipment balancing onsite and oversaw offsite balancing efforts.