Qualifications Summary
Extensive experience in plant engineering, maintenance, reliability, construction and process engineering in the specialty chemicals industry in the capacity of engineer, manager and consultant. Over 10 years designing, supporting and implementing maintenance and reliability improvement programs, developing and using metrics, planning and scheduling, RCFA, PM/PdM programs and CMMS implementation. Over 10 years Plant Engineering experience, including engineering management, site development, capital budget and project execution and maintenance management. Five years experience as construction manager building structures, executing renovations and installing capital process equipment. Background also includes process engineering experience in waste management, pharmaceutical, and equipment manufacturing industries.
Expertise in maintenance and reliability engineering, maintenance planning and scheduling, RCFA, FMEA, preventive maintenance. Practical experience in equipment selection, installation, start up, repair and troubleshooting, project management, unit operations, solids-liquid separations and solids handling.
Experience
Consulting
Principal
Provide project management and process equipment maintenance and reliability expertise to industrial and commercial clients.
- Problem solving coaching and instruction for major mining enterprise
- Root cause analysis
- Failure Modes and Effects Analysis (FMEA) automated robotic packaging line
Chemical and Pharmaceutical Manufacturing
Project Manager
Responsible for managing O&M projects in NE US
- Created maintenance plans and supported scheduling project in sterile utilities operations area for global pharmaceutical manufacturer.
Senior Maintenance & Reliability Engineer
Led maintenance and reliability improvements at internal client manufacturing sites.
- Reduced annual maintenance spending by 7% and achieved total maintenance savings of $5.4MM over 4 years by introducing and establishing equipment reliability and maintenance best practices in the Salt Division’s production facilities. Improved uptime, staffing, pm/pdm programs, stores, planning & scheduling during Datastream CMMS implementation.
- Recommended and led four teams to attack common equipment problems at most Salt sites. Multi-site teams met virtually, identified common problems, shared or developed effective solutions, created best practices. OEM engineers and service techs were commonly members.
- Led project to upgrade existing rotating equipment preventive maintenance program at $2B integrated chemical production facility reducing manpower requirements while increasing equipment coverage. Extracted data from and loaded missing equipment and new pms into SAP.
- Conducted three FMEAs in support of purchase of new equipment.
- Improved plant profitability and operational consistency at specialty chemicals plant in Illinois. Reduced annual maintenance spending by $0.75MM (20%) in three years. Total savings over three years was $1MM through improvements in staffing, stores, planning and scheduling during SAP implementation.
Construction Department Manager
Created and led an internal construction group in a large specialty chemical manufacturing plant. Led 73 salaried and union employees. Annual department budget: $6MM. Project values ranged to $5MM.
- Delivered project costs 20% below outside contractors.
- Reduced serious injuries by 90% over three years through employee involvement. Nominated for VP Award.
- Developed strong reputation among major internal customers for providing effective construction services.
- Completed $3.5MM rheology modifiers project 30% under budget and ahead of schedule. Received commendation from internal business team leaders.
- Developed a contracting process with customers that defined scope, schedule, cost up front
Engineering and Maintenance Manager
Managed discipline and project engineering and maintenance activities supporting five production processes. Supervised 9 engineers, three designers and 15 mechanics. Annual department budget: $3MM.
- Delivered $10MM distillation process improvement project, concept through start-up, on time, on budget.
- Increased resin production 50% through the installation and start up of a flash dryer.
- Improved reliability of unique 75HP VFD on specialized application in polystyrene resin process. Returned unit to spec conditions, improved documentation, spare parts availability and trained mechanics.
Plant Engineer
Managed all engineering and maintenance for 75,000 sq. ft. production and lab facility. Supervised 10 maintenance mechanics, stores clerk and foreman. Annual department budget: $750,000.
- Built 30,000 sq.ft. of labs, offices, maintenance stores and production areas. Renovated production areas.
- Recommended, designed and started up automated de-watering process 40% increase in production.
Coal-Fired Power Plant
Senior Concept Engineer – Performance testing, equipment sizing, pilot testing
Centrifuge Manufacturer
Process Engineer – Field testing, troubleshooting, sizing centrifuges
Education
Master of Chemical Engineering, Villanova University, Villanova, PA
Bachelor of Chemical Engineering, Villanova University, Villanova, PA
Graduate Business Coursework, St. Joseph’s University, Philadelphia, PA
Professional Affiliations
Member, American Institute of Chemical Engineers; Society of Maintenance and Reliability Professionals
Certified Engineer in Training in preparation for professional registration, State of Pennsylvania
Certified Instructor – Apollo Root Cause Analysis, Apollo Associated Services, LLC Friendswood, TX