PROFILE

. Plant engineering and project management experience and a track record of

success in consistent achievement of engineering project goals.

. A skilled problem-identifier and troubleshooter.

. Efficient, organized leader with proven success in coordinating efforts

within internal-external teams to reach and surpass expectations.

. Expert-level skills in mechanical engineering, equipment design, lean

manufacturing and processes.

CORE COMPETENCIES

< Preparation of cost estimates, capital budgets, ROI calculations

including design and direction on all projects.

< Project management, purchasing and supervision of contractors for all

projects to assure completion on a timely basis and within budget.

< Direct supervision of maintenance supervisory staff and monitor

maintenance activities across all shifts to assure appropriate facility

and equipment upkeep.

< Oversee maintenance budget items through computerized management system

(SAP, COGZ, and MAXIMO), inventory control, budget controls, energy

usage, price alternatives, preventative maintenance procedures, purchase

orders and financial reporting.

< Oversee plant facility security programs/procedures including Loss

Prevention procedures, surveillance systems and keying systems.

< Oversee local computer network and telecommunications administration

including equipment installation, major system upgrades, analyzing and

resolving end user hardware/software computer problems and provide end

user training where required.

< Assure compliance and report with all City, State and Federal Regulatory

Agencies and Insurance carriers including EPA, OSHA, NFPA and others.

< Monitor all permit renewal dates and apply for necessary new permits or

renewals where necessary and on time.

RELATED SKILLS

< MS Windows 2000/XP/7 operating environments.

< Autodesk Inventor Series 10.

< Microsoft Office, Adobe PhotoShop.

< LEAN engineering.

< Development of successful cross-functional employee teams.

< PSM/RMP fluent.

< Certified Boiler and Ammonia Refrigeration operator.

< CPMM certification.

SUPPLEMENTARY

< Intrinsic creative talents and lifelong interest in art offer a keen eye

for quality and appealing equipment design and layouts.

< Fluent in Italian, conversant in French and Arabic.

PERSONAL EXPERIENCE

INGENIA POLYMERS, Corp., Houston, Texas (May 2014 - Present)

Ingenia Polymers is an integrated solutions provider for the global

polymers industry. The management systems of the manufacturing facilities

are registered to the ISO 9001-2008 standard. It is composed of two

complementary business units - The Primary Producer Division provides

thermoplastic custom compounding, size reduction, custom densified additive

blend solutions and product development support for resin producers; the

Proprietary Product Division provides engineered products such as white and

black Masterbatches, additive and color concentrates as well as specialty

products that serve the rotomolding, pipe and film market segments. It has

manufacturing plants in Canada, Saudi Arabia and in the USA.

Plant Maintenance Manager

< Manage the daily maintenance aspects of manufacturing, environmental and

building/facilities on a 7-day, 2-shift production schedule.

< Overhauled the PM program and developed 63 primary tasks that replaced

other numerous non-qualitative ones.

< Work extensively with SAP system creating new databases to streamline

inventory volume, create proper equipment and subassembly structure and

account for all issues with workorders.

< Focus on programs to ensure compliance with OSHA and EPA. Promote the

STOP and safety programs and am heavily involved with addressing and

reducing HAZARD ID's.

< Substantially reduced downtime, overtime, M&R and inventory costs.

< Redesigned and implemented several problematic components and systems

using AutoCAD.

Achievements:

Sustainability: Reduced liquid nitrogen consumption from $65,000

to $9,000 per month; water consumption by 15%;

compressed air leakages by 63%.

Design and Saved an estimated projection of $259,000 annually

trouble-shooting: in elimination of equipment breakdowns; in-house

exchanger cleaning and compressed air equipment

maintenance.

Inventory, weekly Inventory - 80% reduction; M&R - 50% reduction;

M&R costs and maintenance downtime - 24% to 5.89%.

downtime:

PERDUE FOODS, LLC, Perry, Georgia (Apr 2013 - Jan 2014)

Perdue Foods produces quality branded uncooked and cooked chicken, ready-to-

cook whole birds and parts, turkey and pork products distributed through

retail, food service and international customers. Their offerings include

the leading names in natural chicken and turkey; antibiotic-free chicken,

turkey and pork; and USDA-certified organic chicken - including the

PERDUE, HARVESTLAND and COLEMAN NATURAL brands. The complex plant in

Perry, Georgia consists of the "kill" plant and the "cook" plant that

produces refrigerated prepared chicken including SIMPLY SMART Chicken.

Complex Plant Maintenance Manager

< Manage the daily maintenance aspects of manufacturing, refrigeration,

environmental and building/facilities departments on a 7-day, 2-shift

production schedule.

< Introduced and developed a formal training program (in partnership with

Central Georgia Technical College) for the maintenance department turning

around "tribal knowledge" into fundamental knowledge.

< Developed and implemented plans to reduce the consumptions of nitrogen,

carbon dioxide, water and electricity.

< Focused on the programs to ensure compliance with OSHA and EPA. Promoted

the STOP program and was heavily involved with achieving a million man

hours accident free environment.

< Substantially reduced downtime, overtime, M&R and inventory costs.

< Initiated an in house fabrication and machining workshop; brought current

several major out-of-date AutoCAD plant drawings; redesigned and

implemented a standard for conveyor bull-nosing to prevent product

wastage.

Achievements:

Sustainability: Reduced liquid nitrogen consumption from $65,000

to $9,000 per month; water consumption by 15%;

compressed air leakages by 63%.

In-house design and Reduced farmed out fabrication services from

machining: $25,000 to $1,000 per month; contractual plant

construction work from $79,000 to $3,000 per

month.

Inventory, weekly Inventory - 6% reduction; M&R - 32% reduction;

M&R costs and maintenance downtime - 12% (18% to 5.53%).

downtime:

Increased Maintenance workforce from 45 to 33; achieved a

Maintenance 95% PM compliance (increased from 63%), introduced

abilities: an "M-16" emergency work auditing to encourage and

establish root-cause analysis.

ARMOUR-ECKRICH FOODS, LLC, St. James, Minnesota (Nov 2010 - Mar 2013)

Armour-Eckrich is part of Smithfield Foods, Inc. which is the world's

largest pork producer and processor. Headquartered in Smithfield, Virginia,

it runs facilities in 26 U.S. states through companies such as, Eckrich,

Farmland Foods of Kansas, Gwaltney of Smithfield, John Morrell, Murphy

Family Farms of North Carolina, and Premium Standard Farms. It also has

operations in Mexico and in 10 European countries. The plant in St. James

produces, amongst other refrigerated prepared meats, "LunchMakers" which

compete with Oscar Meyer's "Lunchables".

Plant Engineer

< Manage the maintenance aspects of manufacturing, refrigeration,

environmental and building/facilities departments.

< Develop plans (with the corporate director of engineering and project

engineer) to reorganize the production lines by adding 2 new lines and

removing one. Added more robotic automations to the production process.

< Focused on the PSM program to ensure compliance with OSHA and EPA and to

safeguard the plant from ammonia releases.

< Initialize a training program hiring program for mechanics to ensure

proper skill and aptitude levels are maintained.

< Introduced new technologies to the plant and led by planning, justifying

and implementing continuous improvement.

< Successful turn-around in waste water treatment - lowering chemical

levels to below city levels.

Achievements:

Environmental Awarded By SMITHFIELD FOODS in 2011, 2012 for

Excellence Awards: environmental achievements which included a total

of $1.7M savings in water and electricity

consumption.

In-house design and Modified OEM parts for better reliability and

machining: generated drawings of OEM parts in order to

re-source for better pricing and lead time.

Inventory and Inventory reduced by $0.5M through training and

weekly M&R costs: proper root-cause investigation. M&R costs

reduced $.25M in 2011 and maintained during 2012

even with a new line.

Increased Mechanic Reduced the maintenance workforce from 37 to 28 by

abilities: evaluating needs and performances, focus on

quality (not quantity) of PM tasks, auditing

performances and increasing department moral

through fairness and consistency; maintaining a DT

percentage of 2.6%.

TYSON FOODS, INC., Houston, Texas (Feb 2008 - Oct 2010)

Tyson Foods is one of largest U.S. marketers of chicken, beef and pork to

retail grocers, broad line foodservice distributors and national fast food

and full service restaurant chains; fresh beef and pork; frozen and fully-

cooked chicken, beef and pork products; case-ready beef and pork;

supermarket deli chicken products. The plant in Houston produces

Refrigerated Prepared Meats.

Complex Plant Engineer

< Manage the maintenance aspects of manufacturing, refrigeration,

environmental and building/facilities departments.

< Develop master plans (alongside corporate project engineering) for

consolidating two plants into one (May 2009 - October 2009).

Achievements:

Main equipment Totally rebuilt three batch cookhouses' "walking

retro-fitting: beams". Saving of $330,000 due to designing and

building in-house v. contractual services.

In-house machining Founded a machine shop and created a "Task Force

and problem Team". Machine shop services avoided costs up to

solving: $421,000 annually and the TFT was able to reduce

downtime from 29% to 12%.

Reduction of Inventory reduced by $1.3M through Team Member

inventory and training (morphing from "part changers") and

weekly M&R costs: proper supervision (Expect only what you Inspect).

NUTRAMAX FIRST AID PRODUCTS, INC., Houston, Texas (Apr 1997 - Jan 2008)

Manufacturer of medical devices such as Orthopedic and Eye Care Products;

Operating room sponges and Surgical Cauteries; Wound Dressings and Wound

Preparation products; Rolled Gauze, Pads, Bandage Rolls and Tapes.

NutraMax is an ISO 9001/AS9100 Quality System certified organization.

Plant Engineering Manager

< Manage all packaging and processing projects including equipment design,

layout and installation.

< Develop master plans for manufacturing sites including China and

Massachusetts, including HVAC ducting, with inline humidification and

dehumidification systems; chilling, vacuum, compressed air and press

effluent plumbing; remote environmental and equipment monitoring and

control.

< Support marketing initiatives for innovation and renovation of products.

< Oversee tooling and machining process including injection mold

development and device assembly process improvement.

< Manage and support engineering, local IT, maintenance and facilities

teams.

Achievements:

Raw material waste 36% saving ($258,000 directly, $46,000 indirectly

reduction: annually).

Reduction in Totally eliminated.

stock-outs:

Reduction in 58% increased uptime (annual saving of 2,960

machine changeover: maintenance man hours and equally avoided

overtime production overhead).

In-house equipment 40% labor reduction due to equipment automation.

design and ROI less than 2 years.

fabrication:

Transfer supporting Massachusetts to Houston. 87,000 sq ft area for

production floss, toothbrush blister pack production. Three

divisions: production cells with 5-lane converging conveyor

systems designed and built in-house in Houston.

Project turnaround in an exceptional 3-month

period.

Manufacturing plant China. $15M project involving 40 major pieces of

start-up: equipment, 10 strip machines designed and built

in-house in Houston. Project turnaround 2 years.

Most cross-trained Superbly fortunate to be surrounded by skill and

staff: talent. Able to motivate and nurture a team that

is empowered and cross-trained in mechanics,

machining, drafting, electrical and store room

activities.

ATLANTIC PACKAGING PRODUCTS LIMITED, Scarborough, Ontario, Canada (1989 -

1997)

Atlantic Packaging is the only major Canadian-owned corrugated packaging

product manufacturer supported by two linerboard mills and seven converting

plants. Atlantic Packaging is one of the major private label towel and

tissue products and control label producers in Canada.

Plant Engineering Manager

< (1989 - 1991) Manage all engineering projects for ALUGLAS including

vacuum metallizing, laminating and delaminating aluminized foil, 12-color

flexographic/Rotogravures printing and die cutting.

< (1991 - 1993) Manage all engineering projects for COLORPAK including

high and low density polyethylene extruders, blow film lines, compounding

lines, printing stations and box strappers.

< (1993 - 1997) Provide technical support for maintenance and non-

technical team members.

< Perform as temporary quality assurance engineer.

< Manage and support engineering, maintenance and contractors.

< Develop master plans (including 3-D modeling using AutoCAD) for the

Tissue Converting plant.

< Key highlights:

. HHT and BRT converting and Folder Napkin/serviette/Facial

Lines,

. Kongskilde trim removal piping system including closed loop

chilled water system,

. Core bandoliers, dust collecting rooms,

. Conveyance systems using Flex-Link, K-Flex and Rapistan

modular components to create multi-elevation, multi-lane

circuits,

. Palletizing systems using FANUC robots Flex-Link Modular and

conventional methods, sorting and discharging, vertical and

horizontal carousels.

Achievements:

Design and fabricate 250% faster than other up-enders on the market.

revolutionary BRT 60% less space requirement for installation.

up-ender: 80% less expensive than other up-enders.

Design and fabricate "On-the-fly" splicing with 12 roll capacity.

customized core 60% gain in uninterrupted core production with

rolls bandoliers: consistent wrap tension and overlap.

Raw material waste 38% waste reduction resulting from equipment

reduction: improvements, strict PM scheduling, astute

trouble-shooting accredited to team involvement

and empowerment.

Education:

CPMM Certified Professional Maintenance Manager (2011)

Brown Belt Level Smithfield maintenance and engineering training

(2011)

B.Sc. Mech.E. University of Calgary, Alberta, Canada (1989)

SAMPLE PROJECT ENGINEERING PORTFOLIO

R A Y M O N D F M E R C I E C A

Period Area Benefit Goal CIR Approval Brief Description Result Completed, [Y/N] 2013 -2014 Production Marinating Increase product yield 250,000 Retrofit centralized 4-pump vacuum system with halo accumulation and separators Yield increased 27% Y Production Conveyance Reclaim product purge 26,000 Replace belt conveyors with MURZAN pumps, hopper & metal detection Eliminated 100% line waste Y Facilities Basement, Offal Reduce fungal growth, infestations 128,000 Air recirculation system, waste screening, pumping, auger conveyors, denaturing system Reduced RH [99% to 50%], contamination Y 2010 - 2013 Production Capacity Meet market needs 850,000 Install 2 new production lines (MULTIVAC, FORMAX) On budget and on time Y Production Automation Reduce labor, consistent packaging 430,000 Install 2 FANUC robot stacking/palletizing lines 24-Operator reduction Y Waste Water Treatment State compliance 230,000 Retrofit DAF, drains, filters, pumps, press, H2S, CO monitoring Eliminated fines and citations Y 2008 - 2010 Production Plant consolidation Bring 3 plants under one roof 44,000,000 Plant expansion (additional 375,000 sq. ft.) including mezzanines, clean rooms, warehousing. Eliminated transportation costs; reduced changeovers; reduced cross-contaminations Y Production Cookhouses Increase equipment reliability 1,200,000 Completely redesigned and installed "walking beams" for handling heavier loads (60" v. 48" log length), automatic loading and unloading of racks Reduced labor due to automation; increased uptime Y Utilities NH3 Engine room Increase refrigeration capacity 3,400,000 340,000lb automated refrigeration system including compressors, evaporators, condensers, high and low temperature lines, control banks, receivers, etc. On budget and on time Y 1997 - 2007 Production Outsourcing Establish a new manufacturing plant in China 15,000,000 Redesigned faster medical devices equipment; managed the hiring of resources and mechanics; new plant startup Overcome culture and customs issues; on budget and on time Y Production Outsourcing Establish a new manufacturing plant in Mexico 10,000,000 Dismantled and reassembled medical devices equipment; managed contractual resources; hired and trained maintenance staff; new plant startup Overcome culture and customs issues; on budget and on time Y Production Capacity Cheaper labor 4,000,000 Transfer from Massachusetts to Houston; dental floss division startup On budget and on time Y 1989 - 1997 Utilities Winders Trim removal 480,000 Install overhead air system, pumps, cyclonic separators, balers Space & labor reduction, efficient recycling Y Production Process Enhancement Space saving, reliability 120,000 Design and patent new "up-ender" equipment; installed 5 units No moving parts, 100% reliable, fraction of competitors' cost Y Production Conveyance Space conservation 1,500,000 3-mile total length flow conveyance including elevators, mergers, diverters, palletizers, FANUC robots Under budget and on time Y

Contact this candidate