Engineering/ Maintenance Leader (273485) BSME, PE / Specialty Chemicals, PSM, Medical, Food / WIll relocate

Accomplished Maintenance/Engineering Leader with 20 years of experience. He is a BSME and is a PE Professional Engineer. He has led maintenance teams of up to 56 team members. This metrics-driven leader has a proven track record of driving strategic initiatives and delivering exceptional improvements for his employers. He has worked in PSM environments across multiple industries that include specialty chemicals, medical products, and food manufacturing. He has held progressive roles leading maintenance, production, and engineering teams to achieve some IMPRESSIVE results. He is highly skilled in developing and executing comprehensive strategies, that result in improvements in safety, quality, customer satisfaction, and performance.

This Game Changer is currently is currently employed, but is interested in CONFIDENTIALLY exploring new opportunities and he is willing to relocate. This is a unique opportunity to engage with a Leader who can pull together maintenance, engineering, and production to turn your manufacturing plant into a Money Machine! He has been there, done, that, and can do it for you! His impressive experience includes?

• Developed cost savings trackers with staff and spare parts to save 5.7% or $3.6M on $63M overall parts, supplies, and solvents budget in 2023 through reduced parts cost/use rate and optimized solvent usage.
• Responsible for PSM-covered equipment on the operational side, collaborates with HSE and Facilities teams regarding PSM elements, asset management strategies, MI testing, criticality assessments, PM reviews risk-based methodology.
• Resolved and addressed multiple quality issues and made significant improvements with blister pack leakers by redesigning our temperature calibration device, reducing non-conformance related issues by 80%
• Worked with the controls group to develop/automate the Mean Time To Respond-Resolve-Repair (MTTR3) system which allowed us to measure Production Technician and/or Electro-Mechanic response times to resolve faults or repair equipment. This MTTR3 process is instrumental in improving and sustaining world class OEE performance.
• Innovative solution implemented with OEE Electro-Mechanic collaboration to resolve chronic saline leak issue.
• Lead the maintenance team for Dailies Total 1 equipment platform the team consisted of 56 Electro-Mechanics supporting the equipment 24/7 on 4 – 12-hour shifts.
• Developed tracking for significant key performance indicators like reactive work hours vs preventive maintenance which drove significant improvement in the PM program.
• Implemented the predictive maintenance process by using ultrasonic, motor torque and sequence time monitoring.
• Implemented a maintenance radio program for a more efficient response time
• Manage all maintenance activities at the plant which was a PSM environment
• Responsible for 37 maintenance personnel which includes 4 supervisors and a planner working to improve the reliability of all production equipment in a PSM environment. This includes ammonia refrigeration systems,
• Experienced with TPM and developed key activity indicators such as PM’s/month, PM Completion %, along with key performance indicators like Breakdowns/month, Breakdown Loss %, Emergency work % and Maintenance Cost / Lb produced as-well-as Mean Time Between Failures (MTBF) and Mean Time to Repair (MTTR).
• By focusing on preventive maintenance procedures/frequency, specific equipment training and accountability we improved plant equipment efficiency 62% to 81% in last 12 months.
• We also reduced the overall personnel in the Technical Services Department from 55 to 37 by assessing skills using written and hands-on performance assessments.
• Performed operational risk assessment + 4M (Man, Machine, Methods & Materials) and reduced plant conversion cost from $0.506 in 2013 to $0.445 in 2014 for a $4,270,000 net savings which is $3M under budget.
• Currently labor is 9.7% below budget along with maintenance parts and outside labor 16.0% below budget.
• Using sub-metering data analysis, we
o Reduced our energy consumption by 8.5%
o Reduced water cost by 22.8% through reduced overall loading and lower surcharge.
• In 2014 our team is in 1st of 11 Plants in 6 performance metrics: Safety, Quality, Growth, Cost, Service and Culture.
• Responsible for 30 maintenance personnel which included 4 Team Leaders on 3 shifts.
• Developed KAIs and KPIs for maintenance department and personnel.
• Safety council member with 2 recordable in 2012, 1300+ days without an LTA and 290+ days without a recordable.
• Key team member of the Atlanta Ingredients plant which finished 1st of 12 North American Plants in 8 KPI metrics.
• 2012 cost savings exceeded our $890,000 target by 150%.
• The maintenance team was under budget every year based on adjusted finish goods produced.
• Auditing body BRC grade “A” for the last 3 years.
• Part of a 6 Sigma team of Equipment Productivity – CIP we decreased production cost by 32% over the previous 4 years while reducing maintenance expenditures.
• Responsible for facility engineering as well as plant maintenance at this intermediate chemical plant (PSM plant).
• Worked extensively on the PSM program at this facility with 5 highly hazardous chemicals.
• Managed 25+ team of union mechanics and engineers. Involved in union negotiations.
• Implemented a Computer Maintenance Management System to track work orders and PM’s

• Maintenance Team Leadership – 56
• Chemical Manufacturing Maintenance
• Process Safety Management (PSM)
• Cogeneration Powerplant Maintenance
• Power & recovery boilers
• Multicraft Maintenance
• Zone Maintenance
• Multi-plant Maintenance Operations
• Manufacturing / Production Maintenance
• Mechanical Maintenance
• Electrical Maintenance
• Electro-pneumatic / Pneumatic Controls
• Large Equipment Refurbishment
• Dismantling / Moving Equipment
• Equipment Commissioning
• Resolving Recurring Downtime Issues
• Troubleshooting Equipment
• Repairing / Rebuilding Pumps
• Improving Asset Efficiency
• Improving Mechanical Integrity / Uptime
• 3D CAD / AutoCAD
• CMMS Maximo
• Kronos Software
• Autodesk Inventor
• Solidworks
• Minitab
• Continuous Improvement Programs
• Design Review of MOC / Technical Documents
• Developing Capital Project Budgets
• HAZMAT Reports
• Planning / Executing Turnarounds
• Planned Outages / Turnaround experience
• Planned Preventive Maintenance (PPM)
• API Codes
• ASME Codes
• HAZOPS
• Implementing Lean
• ISO9000
• OSHA Regulations
• Lockout / Tagout
• Maintenance Leadership
• Planning / Scheduling
• Maintenance Training
• Mechanical Integrity and Quality Assurance (MIQA)
• Performing Design Review For All MOC Related To Mechanical Equipment
• Preventative Maintenance
• Project Management Scheduling
• Reading Schematics / Blueprints
• Safety Training
• Selecting Personal Protection Equipment
• Supervising Contractors
• Developing Standard Operating Procedures
• Ensuring Process Equipment Application Suitability
• Ensuring Spare Parts Meet Code
• Equipment Utilization Metrics
• Establishing Written Procedures
• Managing PM Work Orders
• Eliminating Work Order Backlogs
• Mechanical Integrity Maintenance Training
• Mechanical Integrity Programs
• Maintaining ASME Certifications On Pressure Vessels
• Reducing Mechanical Breakdowns
• Reliability Centered Maintenance
• Maintaining Mechanical Integrity Documentation
• Maintaining Process Equipment Inspection Documentation
• Maintaining Service Documentation
• Asset Integrity Management systems
• Current Good Manufacturing Practices (cGMP)
• Failure Analysis Investigations
• Finite Element Method
• Identifying Equipment Deficiencies
• Improving Equipment Reliability
• Inspection / Testing Task Planning
• Inspection, Testing and Preventive Maintenance (ITPM) plans
• Management of Change (MOC)
• Operational Hazard Analysis
• Replacement In Kind Parts Program
• Risk Analysis
• Root Cause Failure Analysis
• Corrosion Analysis
• Design Failure Analysis
• DOE
• Fatigue / Creep Analysis
• Fault Tree Analysis
• Non Destructive Testing
• Testing Process Equipment
• Human Error Analysis
• Thermal Stress Analysis
• Thermography
• Vibration Fatigue Analysis, alignment
• Training Contractors On Processes

Education:

Bachelor of Science – Mechanical Engineering, North Dakota State University
Professional Engineer (PE) Certification, State of Georgia