Initiated on-going safety programs to improve plant ergonomics, guarding, lock-tag-verification, and pedestrian forklift separation. Recruited, hired, and developed a team of four to manage the plant’s engineering and technical service departments.Developed and sustained a rotating co-op student program with local universities.Championed culture change with respect to safety, workplace environment, innovation mindset, and data driven decisions.Led the plant in implementation of new product features via an Agile Scrum approach for HDZ Timberline and PAR granules.Implemented plant’s Environmental Management System (EMS) for all local, state, and federal permitting for routine reporting including NOx Emissions, NPDES, GACT, Tier II, & Form R.Implemented plant’s Inspection Management System (IMS) for fired & unfired pressure vessels and tank & silo integrity.Managed FM Global annual reporting and improvements.Managed and executed strategic capital projects. Examples include:•$7.8MM Robotic palletizers for new warehouse expansion.•$3.0MM Industrial hygiene system upgrades including plant vacuum system.•$2.2MM Granule delivery system automation upgrade including bulk solid mass flow system improvements.•$1.2MM Electrical infrastructure replacements including plant switch gear & electrical room transformers.•$0.9MM Plant compressed air system upgrades.Planned and managed plant’s annual $1.0MM capital budget. Project examples include:•Automated weight control system.•Hot oil pump upgrades.•Shingle cutter system upgrades.•System control upgrades (Obsolete drives, PanelViews, & rectifiers).•Plant infrastructure upgrades (Parking lot, roofs, elevators, structural sectionals, living space renovations).

Budgeted and tracked the plant’s annual bill of materials for optimal raw material utilization (MUV).Budgeted and tracked the plant’s annual production rates for optimal overall equipment efficiency (OEE). Increased production rates by implementing process changes as developed through trials & capital project implementation:•Increased line speed by 20% ($1.6MM) by reengineering a return system bottleneck and maintaining quality standards.•Saved $500k annually by redesigning laminate and sealant adhesives to address a product quality issue.•Saved $10k annually by reducing release tape application variance to allow for a width reduction.•Reduced waste by $40k annually by implementing a barcode scanner system to detect release tape defects.Led the plant through a Process Driven Culture shift that included implementation and sustainability of the following:•BrainCube data analytic software to provide centerline live dials to guide operators in process variation reduction.•Wonderware Manufacturing Execution System (MES) for real time production downtime, slowtime, and scrap data input and OEE analysis for process improvements.•Gauge Repeatability & Reproducibility guidelines for monitoring of measurement and instrumentation variance.•GageList web portal to track and ensure all quality instrumentation calibration is up to date.•Centerlined mechanical tolerances for critical manufacturing equipment to ensure proper preventative maintenance.•TrackVia web portal for knowledge based documentation of all corrective actions and preventative actions (CAPA).Provided 5S safety program contributions for plant evacuation system and various process flow systems.

Responsible for day-to-day monitoring of the manufacturing process including process control and process variation reduction. Reduced variation of identified key process parameters up to 25% through implementation of inline control instrumentation and improved testing methods. Received Team Achievement award for efforts in reducing manufacturing plant’s overall process variation while initiating product seamlessness with a neighboring plant to leverage supply chain advantage in the northeast region.Developed of a throughput capacity assessment that identified a long-term plan to address key bottlenecks at the plant.Conducted several complex multi-variable trials (MVTs) to analyze sheet construction variance and improve overall raw material utilization. Trials included:•Seasonal temperature effect on granule loading. •Granule material oiling effect on visual quality.•Coating thickness cross machine variance measured using a tertra-hertz web-based gauge.Implemented new quality laboratory equipment to measure exposed asphalt and granule color to provide an objective and consistent measurement for monitoring product quality instead of using the subjective human eye.Provided 5S safety program contributions for gel blankets & spill kits locations

Worked in the process engineering department as a manager of several vital projects that directly affected the company’s main products of FDA regulated lactate sensors and blood pathogen reagents. Provided independent leadership and ownership of projects with use of reporting tools on two main assignments: developing a capacity model for lactate sensors and implementing a companywide replacement of obsolete equipment. Presented formal project discussions to process engineering department, site head, and senior management regarding progress, statistical evaluations, and future recommendations. Generated standard operating and equipment procedures, experiments to determine failure modes and root causes, manufacturing process investigations with Kepner-Tregoe tools, training of manufacturing employees, and business orientated short-term assignments.

Worked with the group supporting the manufacturing of bis-phenol-acetone (BPA), a precursor to polycarbonate, that also evaluates catalyst and conducts various experimental investigations. Prepared various number of catalyst procedures for running batch reactions used to evaluate the catalyst. Analysis included sample preparation and testing for gas and liquid chromatographs.Conducted an equilibrium experiment on an important reaction in the BPA process. Other experiments included investigations on catalyst sizing and sulfur poisoning of the catalyst. Designed, developed, and ran various procedures involved in the experiments mentioned above. Trained other employees and the new intern with my responsibilities.

Prepared various types of samples and performed analysis, including zeta charge, percent solids, thermal analysis, gel permeation chromatography, particle size, microluminometer, and autoclave. Supported the Analytical Chemistry Team, Engineer Team, and Microbiological Team. Responsible for all of microbiological project testing including methods development, analysis, documentation, and presentation. Trained other employees in microbiological procedures and responsibilities.