SUMMARY

• Motivated energetic chemical engineer with extensive manufacturing experience and strong track record of process improvement, product quality improvement, cost reduction, problem - solving and small project management. Application creator using Excel, OSI PI, ODBC and Visual Basic to provide meaningful actionable information from raw data from multiple sources.

AREAS OF EXPERTISE:

• Integrations
• Software Development Life Cycle (SDLC)
• Project Management
• Systems Engineering
• Design and Development
• Quality Assurance

PROFESSIONAL EXPERIENCE

Confidential

Lead Process Engineer

Responsibilities:

• Improved rates and yields over 4 different manufacturing lines used to produce the sites most critical product, increasing output by more than 20% and generating millions of dollars of profit. Led team though detailed process analysis and improved procedures, control system (DCS) operations, instrumentation, and equipment.
• Designed and created a plant-wide material balance application with drill down capability to quickly perform material balances across multiple orders and lines, improving the detection and correction of yield problems.
• Designed and employed Focus EMI dashboards across site for real time monitoring of quality and process parameters. Worked through a challenging implementation due to the large number of products made weekly and their diverse test requirements.
• Designed Excel application to forecast weekly volumes and productivities from a complex business forecast, improving the data quality and reducing the time required to process it by 12 hours per week.
• Streamlined reporting of each lines production/quality data into Team Guru by designing a workbook and database for automated export of data, reducing the time required for the process by 10 hours per week.
• Provided template for the conversion of 800+ Word based Confined Entry Procedures to Excel. Automated the change process for ECPs, saving hundreds of manhours each time changes were made.
• Automated a critical analysis of our waste treatment system using Excel and PI to support toxicity investigations and to provide data for the design of a new solids waste collection system which will be implemented soon.
• Developed Excel based shift status reports for each area incorporating quality, rate, and downtime data and automated emailing. All data was archived in our PI system where it could be easily retrieved and viewed.

Senior Production Engineer

Responsibilities:

• Replaced high maintenance semi-automated drum deck with a simple manual one resulting in 2% increased uptime on the line.
• Modified DCS logic after discovering a longtime issue with the seed addition step that increased improved batch accuracy and increased yields by 2%.
• Increased bead rates by 15% and reduced downtime 3% by replacing the high-maintenance oft-plugged dispensing unit with a direct feed.
• Created Excel automated dashboards for real-time monitoring of key process indicators (KPI’s), rate, recovery and quality resulting in greatly improved response to issues that impact manufacturing cost.

Manufacturing Improvement Engineer

Confidential

Responsibilities:

• Co-led a team that improved rate 35% in a key product line. Applied detailed analysis to identify multiple bottlenecks in the line and eliminated them through modifications in DCS logic, procedures, instrumentation, and equipment. Applications were created for batch reporting, detecting leaks, and detecting plugged strainers. Recognized monetarily by the company for the work done on that team. Improved plant operability by designing reports using Excel automation and ODBC to integrate the data across our various databases. The site relies on them heavily to this day. Reports created for quantity, quality, material balances, batch makeups and more.
• Provided template for migration of 800+ SOIs from free-form Word document to standardized workbook as an instrumental part of a small team. Automated the Excel based SOIs to add functionality which included automatic transfer of operating targets and control limits to PI when product changeovers occurred. The control limit data was used with PI SQC for real time monitoring or process data with alerts.
• Driving force behind our MMDD (Mobile Manufacturing Data Delivery) project which created a standard for our PI user displays. Created standardized PI displays across the entire plant - line overview, unit operation. and team page. Created PI alarms, PI SQC displays, and many real-time PI calculations and totalizations. Earned six-sigma black belt through my work on MMDD.
• Co-led a rate and recovery entitlement program that preceded OEE called RARE. The program focused on identifying and running the process bottleneck non-stop. Created automated workbooks for each line to calculate downtime each shift - operators entered that downtime in MES using downtime codes and comment.
• Replaced near-obsolete information systems prior to the year 2000 as key member of a small cross-functional team. The implementation included new SAP, LIMS, PIMS and PI systems.