Dean Broglie, P.E. Email & Phone Number

Russellville, Kentucky, United States

Developed and executed facility annual Capital Plan ranging between $5 to $8M/yr under the authority of the Vice President of Operations based on limited Capital and establishing priority based upon risk.Presented Capital planning requests and related justification to the Executive Vice President of US SteelSuccessfully managed annual capital budget without spending overruns.Led department staff consisting of project managers, electrical, and mechanical engineers. Developed and mentored staffing sourced from graduate, experienced engineer, to project manager level competencies.Replaced a 250,000 gallon, 150’ high gravity water tank on a parallel fixed speed pump system with a 12,000 gal ground level dual function surge and hydropneumatic tank and transitioning the pumps to variable speed to provide 0 to 10,000 gal/min service. This project eliminated a seismic hazard presented by the high tank, preserved pre-1914 water rights on a water source that would cost $3M/yr from an alternate source.Related to the aforementioned, replaced a 1950’s era fish screen on the intake with a new design that met state and federal requirements while preserving the same benefits as well as complying with the National Pollutant Discharge Elimination System (NPDES) permitting renewal requirementsCompleted many projects that were justified to eliminate environmental risks or improve compliance. Examples include replacement of fiberglass acid tanks, seismic retrofit of steel, rubber lined vertical acid tanks, double wall tanks, piping, and related efforts to isolate caustic and acid fluids, secondary containment, new vehicles and retrofit efforts to address diesel fleet emission reductions on wide range of heavy hauling vehicles up to and including 50 ton capacity.Completed many projects that were justified by extending the useful life of an existing asset that would otherwise threaten shutdown of operations or significantly increase the cost of operations.

Led division’s operating and maintenance staff in maximizing the operating performance of the Tandem Cold Rolling Mill with respect to safety, quality, productivity, cost, and general efficiency. Leveraged project and engineering skills in an operating management role.Designed and implemented new tank agitators for an oil water emulsion to replace ineffective low diameter high rpm units which vastly improved the consistency of the operation with respect to friction, stability, and consistency in the rolling operation.Utilized finite element analysis to design and fabricate aluminum expansion rings for the purpose of mandrel expansion and calibration to a known diameter.

Developed and executed major capital projects ($3-$7M) under the authority of the Division Manager of Technology. Personally saved $1M and $2M during design phases after authorization on two projects by finding more cost-effective solutions than that planned at time of authorization.Developed project objectives, scope, conceptual solution, budget, schedule, and appropriation authorization request. With funding authorization, executed engineering of process/machine design and/or construction, procured specification-based equipment/construction contracts, executed construction/implementation and commissioning while minimize the impact to the operation.Lead Mechanical Engineer with a depth of competencies in machine design and manufacturing processes. Depth competencies include CAD/FEA, static and dynamic structural analysis, fluid dynamics, kinetics, kinematics, powertrain, process system, project benefit analysis, and productivity constraint. Breadth competencies include hydraulic and pneumatic controls, thermodynamics, and heat transfer.Developed and provided machine alignment surveying capability to the organization

Led staff of process managers and shift supervisors to achieve business plan targets with regard to safety, product yield, productivity, consumables, repair spending and labor. Operating responsibility included two Electrolytic Tinning Lines and one side trimming unit.Reduced injury frequency from 12 to zero by revitalizing safety procedures and emphasizing procedural accountability at the supervisor and employee levels

Developed and implemented Capital projects. Replaced a low pressure water soluble hydraulic system with a high pressure mineral oil system including multiple valve stands, cylinders, hydraulic power unit, and interconnecting piping. Replaced an unsupported uncoiler mandrel with one supported by an outboard bearing sled.Developed and completed DMAIC Six Sigma projects. Developed scheduling procedures to minimize work in process inventory between subsequent manufacturing processes.

Led staff of process managers and shift supervisors to achieve business plan targets with regard to safety, product yield, productivity, consumables, repair spending and labor. Operating responsibility included a $1.5M ton/year production facility with an operating cost of $35/ton.Led startup of Pickle Line Tandem Cold Mill following a rebuild after it was severely damaged from a fire in 2001. Pre-fire production levels were achieved within 3 months. Replaced inefficient/ineffective component systems during rebuild that improved reliability and reduced operating cost.

Process leader responsible for process optimization and performance. Established process procedures, directed, and monitored performance. Conceived and implemented tangible process improvements. Most notable was a $3M/year productivity gain from modifying software with no capital investment.

This was a rotational assignment to work under various divisions of the manufacturing facility. Supported a Capital project that was in an execution phase. Supported as a rotating shift supervisor of production operations to learn the manufacturing process. Due to prior experience in material flow simulation, provided study in the development of Automatic Guided Vehicle and Automated Crane Systems to replace manned mobile equipment used in transporting steel coils between production units and storage areas.

Broad practice of mechanical Machine Design for various applications in Steel, Glass, and transformer manufacturing as engineering services.Utilized ANSYS Finite Element Analysis to design a custom horizontal support truss which held fluid filled tanks across a significant span in an electrolytic tinning line. The truss design fell to the responsibility of the mechanical department due to the geometric access required of rolls, piping, motors, anodes, etc. ANSYS was used to verify the member sizing and geometry of the truss to verify midspan deflection criteria had been satisfied prior to commencing detail design of the truss.Utilized AutoMod material flow simulation software to provide 3D simulation of the manufacturing movements between and within processes and storage queues. The modeling included statistical variation of processes as well as constraints in the form of speed and acceleration of mechanical cranes or ground vehicles and geometric constraints in storage areas and along transport routes.Utilized excel to provide production modeling to analyze the projected process improvement resulting from addressing specific bottlenecks within the process. The projected improvement was weighed against the cost to address the particular bottleneck as a basis for capital investment opportunity.