Established and executed on long term maintenance strategy and improvement planEnsured PSM compliance by maintaining and regularly reviewing MI program and MOC’s for plant changesManaged Preventative Maintenance program ensuring regular complianceUtilized Root Cause Failure Analysis and FMEA techniques to address major reliability issuesCoached and trained engineers and technicians in plant operations, equipment, and troubleshootingInvestigated and corrected plant upsets reducing plant downtime due to unplanned equipment breakdown by 50%Managed improvements to critical spare part identification and storageExecuted on capital projects based on site plan within budget with 90% on time deliveryManaged planning and execution of plant shutdowns and turnaroundsLed and facilitated PHA, RCMS, and ISO auditsParticipated in and implemented solutions to HAZOP analysesDeveloped and shared “Lessons Learnt” with other sites on reliability solutions identified

Manages operation of PSM, RCMS:2008 and ISO 9001:2015 site with $12 million revenueSpearheaded 5 year manufacturing strategy to best support broad specialty business needsEnsures compliance with federal, MassDEP, and local POTW regulationsDrove business strategy to reduce production cost by 4.3% while increasing volumeIntroduced Overall Equipment Effectiveness to identify and reduce process wasteChampioned roll out of acquiring company values and SHE Principles to site, embedding in the mindsetRevitalized Preventative Maintenance management, documentation, and trackingDeveloped automated report to easily manage Safety KPI metric used at sister-sites of organization

Acted as Interim Plant ManagerManaged scheduling, maintaining 90% capacity and reducing order failure rate 3.1% YOYImproved communications between customer service and plant leading to better customer relations

Scaled up new products safely and efficiently earning two internal awards for new product launchesLed effort to attain ISO 9001:2015 certification for facility for first time leading to no NCR's in first external auditImproved document control and process review tracking leading to PSM improvementsAnalyzed process upsets and identified improvements to increase first pass prime batchesCoached and improved process understanding of operators, supervisors, and interns

Oversaw SOP’s for eight emulsion and solvent reactors to safely and consistently produce quality adhesiveCreated and updated SOP’s, work instructions, CAR’s and PAR’s per ISO 9001 certified standardsFamiliarized and complied with cGMP and USDA standards to meet needs for end use applicationsDesigned and submitted technical AFE proposal for supplemental tank to feed into four solvent reactor systemsFacilitated Process Hazard Analyses, Pre-Startup Safety Reviews for new process equipmentProvided training and troubleshooting on new processes and equipment installationsDetermined feasibility of developmental products based on heat and mass transfer and thermal capabilitiesCreated and updated Process and Instrumentation Diagrams for new processes and equipmentMentored interns, operators and Leadership Development Program Associates in process engineering conceptsAnalyzed process variability according to determine process upsets and target key improvement areas

Employed A3 problem solving and Six Sigma methodology to improve Rapid Roll product line qualityIdentified gaps in raw material return process and deployed PDCA to improve the processLed supplier quality management project, resulting in 65% complaint per million opportunity reductionEstablished Quality Manager role requirements and SOP’s for Rapid Roll product lineApplied Six Sigma and Lean Sigma training to decrease variability and increase product quality

Designed and implemented plant layout in 3,000 sq. ft. laboratory spaceConfigured safety mechanisms for high-pressure fuel cell mechanismsDocumented highest pressure hydrogen compressor test in company history

Examined gas flow apparatus for data accuracy according to roughness ratioCalculated anemometer flow meter surface area through reverse engineeringDemonstrated conduction, natural convection and forced convection on bottle models in COMSOLSummarized that height of measuring probe affects the speed of temperature drop in bottle models

Analyzed complaints on acetabular cup failures by grouping failure modes and comparing resultsCompiled patent research on acetabular cups that prevent ostyeolysisDeveloped assemblies in Unigraphics NX 5.0 for Finite Element Analysis testingDevised protocol for testing acetabular cup models

Prepared plates for PEM fuel cell for heat treatment Engineered procedure to take statistical data on waves in heat treated platesAnalyzed differences in placement of plates in stacks to identify placement of least distortionConcluded variance in stacks was lack of pressure of packaging on middle of plates