Joe Sutkowski Email & Phone Number

United States

Led Vacuum Arc Remelt building recovery after a pressure event led to the total loss of a furnace. Executed rapid response to evaluate building, debris containment, and personnel management Created and executed a $15m recovery plan; managed 11 reconstruction companies with 50+ contractors over multiple shifts to return all equipment to working status on an accelerated timelineLed a VAR critical spare Kaizen event documenting over $1.3m of uncategorized critical spares and provided additional inventory space in site Stores DepartmentManaging a $3.1m Raw Material project replacing and upgrading two defunct briquetting presses and installing two new 500-ton presses, including in house CAD design modifications and building utility improvements Initiated new vendor relationships, reviewed and approved service agreements. Consistent strategic management of vendor relationships

Morgantown, Pennsylvania, United States

Restored a systematic lubricant testing program for critical assets and developed a new Predictive Maintenance pilot program leading to $34k in savings (2022) Determined site wide water quality vendors to be sub-par, interviewed multiple new vendors and consolidated to a single service contract while improving cost and quality of water Led Root Cause Analysis on various equipment related production delaysAssumed additional VAR manager responsibilities due to increasing production demands; expanded weekly melt production from 35 heats to 45+ valued at over $2.1 million additional revenue while maintaining a 24/5 scheduleResponsible for SolidWorks & CAD safety design modifications and improvements to equipment and facilities Initiated an average 3% decrease on furnace changeover by eliminating mold height difference between melt chambersCo-Chair of EHS safety committee (2022), led safety investigations and corrective actionsDeveloped, documented, and improved preventative maintenance programs to support the increasing equipment availability and throughput Capital Project Manager completing projects totaling over $1.4m averaging a 93% cost to budget and zero dollars in cost overruns

West Chester Pa

Project manager for $1.7 million Melt Room upgrade, leading project to reduce/remove Maximum Credible Events and reduce unplanned downtime by 70% Increased first pass rate of Type B Thermocouple from 17% to 75% by improving the raw material selection process and modifying in process specification targets while reducing In-Process metal holdings by 38% ($2.4 million/yr savings)Review incoming specifications and customer drawings for new products to ensure specifications can be met. Lean Manufacturing Coach for Ignition product stream: -Improved yields by 24%, removed costly waste refining step by modifying process -Modified cleaning process to reduce step time by 91% and optimized equipment -Increased initial melt size (by 25%) to reduce total inventory in upstream process and provide versatility in different low running products while maintaining high volume capability for high running products, coupled with previous improvements to a total yield improvement of 86% -Reduced working capital by $2.08 million/yr and P&L savings of $93kOptimized new equipment by bringing a medical tube cleaner up to full capacity by reducing manual manipulation by operators.

Responsible for ensuring the timely start, execution, and changeover of batches and campaigns for multiple bulk Active Bulk Pharmaceutical processes. Initiated manufacturing excellence projects to improve yields above cost model by $250k (2016) and $1.1 million (2017) Organized and initiated investigations surrounding production deviations and finalized documents to close 93% records within 30 daysManaged open investigations and collaborated with other departments to implement effective CAPAs for a 96% Right First TimeOversaw the cleaning and setup efforts of the Setup Team to ensure campaign starts meet aggressive scheduleEstablished changeover SOPs eliminating setup contractors saving approximately $1.5 million per year; improved setup accuracy and reduced changeover time from an average of 25 days to 18 days. Assisted Group Engineering Services Manager in troubleshooting and resolution of plant wide cooling issue. Successfully identified and addressed root cause of issues and prevented repeat occurrences of the issues in second half of year.Pioneer member of the EHS Recognition Subcommittee and participant in EHS Coaching Subcommittee which aided in over 938 days without a LTI and 405 days without a OSHA recordable incident

Warrington, Pa

Supported development and synthesis of a diverse portfolio of custom monomers and polymers in a cGMP settingDeveloped technical reports, reviewed data, and reported project progress to senior managementRefined procedures and scaled up reactions dependent on customer specificationsServed as technical resource on Design and Development Team for medical device polymers

Greater Philadelphia Area

Independently formulated monomers and polymers. Reactions include acrylate polymerization, silanizations, copolymer formulations, and other polymerizations. Recieved ISO 13485 training. Was involved in the process modification of Biomag Super+ to increase customer base.

Morrisville, Pa

Trained in areas of synthetic and silicone polymer chemistry from 22 liters to 500 gallon reactors.Independently carried out reactions, performed purification techniques, and evaluated analytical results of synthesized products. Recieved SCBA, Forklift and ISO 9001 training. Synthesis of bulk and semi-bulk organosilicon and other metal-organic compounds, including their characterization and evaluation.

Clarion, Pa

Provided guidance to customers dealing with unfamiliar problemsAssured available products are accessible to customers Managed inventory and employees

Prepared golf course to meet client expectations, and promoted aesthetics of golf course.

Pa

Advised Customers on proper parts for their personal vehicle. Adapted to the changing needs of customers.

Bs, Chemistry

Activities and Societies: American Chemical Society

Chemical Engineering

Activities and Societies: American Institute of Chemical Engineers