As an Operational Excellence Manager at dsm-firmenich, I lead initiatives to enhance efficiency, productivity, and quality in our vitamin manufacturing processes. My role encompasses managing the site's automation and controls group, ensuring seamless integration of advanced technologies with our continuous improvement efforts.With a strong background in chemical engineering and extensive experience in the food and health industry, I am dedicated to driving innovation and operational excellence. I leverage Lean Six Sigma methodologies to streamline operations, reduce waste, and foster a culture of continuous improvement.Key responsibilities include:- Overseeing the development and implementation of automation solutions to optimize manufacturing processes.- Leading cross-functional teams to identify and execute improvement projects that enhance product quality and operational efficiency.- Developing and delivering comprehensive training programs to onboard new employees and elevate their understanding of our Continuous Improvement Policies.- Collaborating with stakeholders to align automation initiatives with strategic business objectives.I am passionate about utilizing data-driven decision-making and cutting-edge technologies to achieve operational excellence and contribute to the overall success of our organization.

In addition to my primary responsibilities, I took on expanded roles, including:- Leading production planning to ensure efficient operational workflow- Collaborating with procurement and sourcing teams to identify and qualify new raw materials- Developing a long-term strategy to drive sustainable growth and efficiency in the production areaKey Achievements:Recognized an opportunity to position our process as the "plant of choice" for a high-demand product under allocation. By implementing a series of low-cost process improvement projects, we achieved a 40% increase in volumetric output within the first year, generating over $5 million in value with less than $100,000 in capital expenditure. Building on this success, I developed a strategic investment plan to double process capacity over the next three years.

As a Process Engineer for a human and animal spray drying facility, I drive operational excellence through a range of responsibilities, including:- Formulating and executing production campaigns for optimal efficiency- Updating SOPs, P&IDs, and work instructions to ensure process accuracy and compliance- Identifying and mitigating key performance issues through the MOC (Management of Change) process- Monitoring and reporting on availability performance metrics- Applying Six Sigma methodologies to uncover cost savings and enhance process capability- Conducting root cause analyses (RCAs) and troubleshooting for critical safety, quality, and operational incidentsKey Achievements:- Spearheaded and coordinated a cross-functional task force to resolve a critical quality issue, achieving resolution within just four months- Launched an online safety notification app across the site, with over 90% user adoption within the first six weeks- Successfully reduced oversize in the spray drying process by more than 90%, significantly improving product consistency and process efficiency

Scoped, gathered quotes for, and completed MOCs for multiple quality improvement projects to reduce the # of justified customer complaints and to improve the right first time. This included leading a project to scope, purchase, qualify and install a new grate magnet.Obtained my green belt certification by optimizing the release process of a high demand product, a statistically significant reduction of approximately 30-50% was observed. As a part of my role reviewing batch records for release I used visual management tools to help reduce the # of cGMP errors being made in my department by 63%. Wrote/executed/summarized multiple IQ/OQ/PQ's for various improvement projects on the site. Conducted a capability study on the validated parameters for a historically "non-stable" product, and recommended changes to bring process back into the appropriate range. Wrote and updated batch records, SOPs and work instructions to improve procedures and training's to quickly teach operators how to run different processes.

Developed comprehensive valve specifications for use across multiple high-value projects exceeding $150 million, ensuring consistency and operational efficiency. Streamlined the product and service index format for two chemical plants, significantly enhancing user interface, reducing errors, and optimizing future plant planning processes. Additionally, classified manufacturer part numbers for over 50 valve types, refining operator selection and generating an annual savings of $20,000.

At Barry Callebaut, I successfully implemented a 5S organizational system in the factory's spare parts room, enhancing efficiency and organization. Additionally, I developed a comprehensive spreadsheet tracking system to monitor and analyze the costs associated with missing inventory, contributing to improved inventory management and cost control.

Contributed to a dedicated team focused on the preparation and shipment of plastic products for the food industry. Developed a strong understanding of small-scale manufacturing operations, gaining insights into both production workflows and the overall business strategy.