Direct the Automation, Electrical and Instrumentation Engineering and Maintenance of the plant equipment through the supervision of 4 directly and 16 indirectly, plus an on-site third party electrical and instrumentation contractor. Responsibilities include safety, productivity, reliability, training, capital support, capital forecast preparation, and employee development/performance evaluations for immediate subordinates. Attending site leadership meetings, Gemba walks(Safety, Reliability and Support), solicit and value everyone’s contribution and input, and determine and execute department goals in support of the mission of the plant. RCA (Root Cause Analysis) Facilitator. Perform root-cause analysis to resolve chronic/major problems with the reliability of the AEI equipment. Insure priority scheduling and adherence to schedule. Improve instrument reliability through the use of AMS, trials and upgrades. Execute annual shutdown, and insure that black assets are healthy.

Direct the engineering and maintenance of the plant equipment and facility and the utilities areas of the plant through the supervision of 6 directly. Responsibilities include creating the PM program, writing PM’s, project management, capital submittals and forecast preparation, and employee development/performance evaluations for immediate subordinates. Improved the communication within the plant by implementing Gemba walks, mechanic line ownership, valuing everyone’s input, and determining plant goals. Started root-cause analysis to resolve chronic/major problems with the mechanical reliability of the plant equipment. Commissioned a new CMMS system (Maximo) moving the organization from paper to excel, then to a computerized program.

Implementation of TPM/CI/Lean including enabling the culture to accept change/improvement as the norm and engage everyone. This included Tier Boards(work done at correct level), 5S, Focus Improvement facilitator, Center-lining processes, empowering operators to do maintenance work/make improvements, creating and leading an Automator group to implement the ideas, partnering with Process Engineers to drive productivity. Led a cross functional energy team responsible for $600M to $1.2MM annually. Responsible for the Electrical Distribution System, including maintenance (preventative and predictive), upgrades, reliability improvements, root cause analysis and contingency planning. Active member of the Local Energy Management Group which includes in depth knowledge of Utility Tariffs, Regulations, ITC Transmission, and MISO. Development of corporate standards for Automation and Electrical. Project Manager/Lead Engineer for a variety of projects including Process and Packaging Installations (New and Improvements). Coordinator for the Plant Facilities Capital Budget. Travel to support other plants and perform energy audits (see page 39 2012 global corporate responsibility report). Member of the Corporate Controls Engineering Team including Promotion Evaluations across the corporation. Mentor numerous engineers within the company. Notable successes include (1) Electrical and controls Lead Engineer for vertical startup of Wheaties process system and later a Cheerios Process system, (2) electrical and controls separation of plant processing/operating areas and advanced electrical technologies resulting in increased system and electrical reliability, (3) development of the corporate standard HVAC controls and operator interface saving just our plant over $2MM per year, (4) Arc flash program pioneer and implanted safety controls risk assessments as standard parts of every project at the plant, and (5) installation of numerous safety related items.

Direct the engineering, maintenance of the plant equipment and facility and the utilities areas of the plant through the supervision of 6 directly and 25 indirectly. Responsibilities include budget preparation, capital submittals and forecast preparation, grievance resolution, employee development and performance evaluations for immediate subordinates. Improved the project tracking and submittal process, including the accumulation of accurate cost estimates, gathering plant input, and determining plant goals. Restarted the preventative/predictive maintenace program at the plant, including vibration monitoring, updating preventatative maintenance work plans and inspection services. Performed root-cause analysis to resolve cronic/major problems with the mechanical reliability of the plant equipment.

Direct the operations of the Power Plant (steam boilers, steam turbo-generators, and plant air), Water Plant (domestic water, process water, and waste treatment), and propane truck loading/storage areas through the supervision of 6 directly and 31 indirectly. Responsibilities include the unit safety effort, personnel scheduling, grievance resolution, employee development and performance evaluations for immediate subordinates. Developed efficiency tests, performed by operators, that resulted in an 8% reduction in energy usage at the Power Plant. Support the implementation of engineering projects and upgrades through the feedback of unit requirements and the formulation of operating procedures with input from operators. Conduct unit incident investigations with root-cause analysis and follow up to insure resolution implementation. Conduct training classes for unit employees on new procedures and equipment. Provide consultation and guidance for instrumentation upgrades/projects at the Tuscola plant (see Electrical and Instrumentation Engineer position below).

Develop scopes, cost estimates, and justifications for instrument and control projects. Design and implement new/revised instrument loops, control systems, and projects. (One project included the optimization of unit furnaces that resulted in 80% less down time.) Troubleshoot plant problems/upsets with follow-up root cause analysis and solution implementation to prevent further occurrences. Supervised and developed a new instrument engineer and the E & I co-op students, including performance evaluations, and aiding in goal setting, communications, and design practice. Conduct in-house training for E & I technicians. Participate in Plant Hazard Reviews and write plant safety and maintenance procedures. Served as E & I coordinator for CMMS implementation. Programmed Allen-Bradley and Square D programmable controllers, single loop digital controllers, and Applied Automation Advance gas chromatograph. Attended hardware and operator interface training for Bailey Net 90 DCS and had exposure to Moore Products DCS.

Responsible for maintenance of the plant equipment and facility through the supervision of 2 directly and 10 indirectly by providing emergency, preventative and predictive maintenance. Coordinated the department safety effort and developed plant safety procedures. Supported plant quality efforts through improved preventative maintenance procedures. Instituted computerized work order system with labor and materials tracking by machine group. Instituted predictive maintenance program using oil and vibration analysis. Encouraged innovation among the department by providing time and materials necessary to implement employee ideas, resulting in more efficient manpower usage and less down time. Prepared annual maintenance budget and conducted performance evaluations for immediate subordinates. Controlled maintenance spending through communication of unit goals. Performed administration and engineering for maintenance, control system and electrical projects

Responsible for all plant Electrical Distribution and Control Systems with their associated projects. Supervised extrusion line installation (both electrical and mechanical), a complete plant electrical systems upgrade, and other projects involving generating project justifications and cost estimates, as well as supervising outside engineering effort and project installations within allotted budgets (largest project = $1 million). Worked with Operations and Maintenance departments to insure continued smooth equipment operation including troubleshooting and process/operations improvements. Investigated and solved equipment related process problems. Worked with Allen-Bradley PLC-5, PID controllers, and intelligent scales, including supervisory control of their functions.

Maintained operations equipment in a highly corrosive environment with a $3.4 million labor and materials budget. Supervised 12 union mechanical repair personnel directly and 20 indirectly to provide emergency and preventative maintenance on department equipment. Implemented a computerized record-keeping system to track parts usage and parts life. Developed machine trouble-shooting manuals for the mechanical repair personnel. Interacted directly with Engineering and Maintenance on new machine installations and major repairs. Supervised 75-person department in absence of supervisor. Counseled employees and took disciplinary action as necessary.

Coordinated and supervised the electrical design effort for the Columbus plant. Designed control systems and power distribution systems. Wrote controller programs for all phases of production automation from Forming to Finishing. Programmed and implemented with Allen-Bradley, Texas Instruments, and Honeywell programmable controllers and Camco motion controllers. Supervised and performed troubleshooting for new machine installations. Interviewed, hired and evaluated the department's Electrical Co-op students. Recognized as an outstanding instructor for in-house training classes. Wrote manuals for new equipment.