Barry S. Ramey
Buffalo Grove, IL 60089
Phone 847-***-**** E-mail acgi0i@r.postjobfree.com
Career Summary
Analytical, team driven, results-orientated management professional with
extensive progressive engineering experience. Recognized as an exceptional
Project Leader whose teams exceed project goals. Known as an innovative
problem solver utilizing Six Sigma Statistical Tools. Strong Facilities,
Maintenance, Lean Manufacturing, and Industrial Engineering background
including OSHA, EPA, Safety Management, in a cGMP and FDA regulated
business.
Professional Experience
Unilever Chicago, IL November 2011
to Present
Home of the Hellman's Brand Mayonnaise with sales over 1 billion dollars.
Maintenance Superintendent
. Managed the project team for the implementation of the SAP CMMS
Maintenance System replacing the old MP2 CMMS system.
. Managed the installation and startup of the new Energy Center which
included the facilities new Frick Ammonia Refrigeration Systems and
well as the Cleaver Brooks boiler room system. This was a 10 million
dollar project that produced well over 1 million dollars in annual
energy savings.
. Lead the PM Pillar for the company wide TPM program that helped
achieve the Level 1 Excellent Award for the Chicago factory.
. Managed our 3rd party plant stockroom vendor (Motion Industries) in
the development of our CMMS Maintenance Software System which
ultimately drove inventory reductions in excess of $500k in savings.
Consolidated Containers Company Elk Grove Village, IL
September 2009 - September 2011
A 1 billion dollar manufacturer of HDPE containers for the Consumer Goods,
Food & Industrial markets.
Maintenance Manager
. Managed cross functional project team for the relocation of the
Stratus wheel extrusion bottle line from our Cincinnati facility to
the Elk Grove facility. Project included working with vendors for line
teardown, reinstall, new EAM tooling, programming of Motoman Robot,
trimmer and reamer rebuild, process validation, and training.
. Developed project scope, layout, and cost analysis for the automation
of the hand packing for the 750ml and 30oz bottles for lines 5 & 7.
Detailed quotes and layouts were created from Motoman and also an
alternate design from Minatech for this robotic solution. Project was
put on hold due to financial constraints.
. Lead maintenance team for the implementation of a new bar coding
system for the parts room which increased the accuracy of the parts
inventory and thus reducing equipment downtime by having the right
parts on hand.
. Implementation of the "5S" program for the maintenance shop, parts
room, and equipment bone yard area by assigning "Town Mayors" for each
area and providing them training and tools in the 5S process
. Enhanced the current CMMS system (Asset Controller) from an inventory
management system to a Facilities and Equipment work order system that
dramatically increased the reliability of facility assets.
Pretium Packaging LLC Peru, IL February 2009 -
September 2009
Manufacturer of PET Containers for the Food and Beverage industry.
Maintenance Manager
. Managed the relocation of our St. Charles Missouri facility to the
Peru facility which included 4 blow molding lines and ancillary
support equipment. Project resulted as a $250K savings for the
corporation.
. Standardized and enhanced the preventative maintenance program which
has resulted in a 10% reduction in unscheduled downtime.
Constar International Inc. Alsip, IL June 2005 -
January 2009
A 1 billion dollar manufacturer of PET bottles for customers including
Pepsi Co. Coke, Dr. Pepper, and Unilever.
Corporate Project/ Process Engineer (Senior Level)
. Project and Process Manager for the development of Constar's "Panel-
Less hot fill bottle ( X4 technology) for SoBe Life Water. Project
included feasibility trials at Sidel France, qualification runs at our
US facilities, and acceptance runs at the customer.
. Managed the transfer of a PET line (SBO16) from the UK to our Ohio
facility including the installation of air compressor, chiller and
piping, and all downstream equipment including palletizer, labeler,
leak detect, and strapper. Also developed blow molding process for the
1 liter and 20oz bottle.
. Managed the transformation of the corporation's Computerize
Maintenance Management System (CMMS) from a stand-alone system (MP2)
to a multi-plant enterprise system (Datastream 7i). This
implementation gave exposure to store room parts as well as
preventative maintenance activities to all plants within the company.
. Managed project team in the re-engineering of the SIG hot fill blow
molding machines which enabled Constar to produce Pepsi's Propel
Fitness Water at a profitable level.
. Lead multi-functional process improvement teams for 14 targeted lines
throughout the corporation. Utilized Six Sigma, Lean techniques and
other process improvement tools to increase productivity that is
projected to save over 1 million dollars in savings and capacity
improvements.
Siebert Engineers Inc. Lombard, IL
September 2004 - June 2005
Temporary contract Project Manager Position performing plant expansions and
facilities modifications for clients such as Kraft, Nestles, and Unilever.
Cloud Packaging Solutions Des Plaines, IL Nov
2003 - June 2004
A $75M contract packaging and machine builder for the Food & Beverage
industry.
Maintenance & Facilities Manager
Managed staff of 22 mechanics dedicated to facilities, preventive
maintenance, and process improvements.
. Directed project team in the installation and startup of PMT's
(Packaging Machinery Technology) "Packaging Line of the Year" for
Kraft's EZ Mac product line that reduced overall packaging cost by
over $2 millions dollars.
. Developed an "Innocence to Excellence" improvement matrix for the
maintenance team to evaluate current strengths and weakness of the
group that ultimately paved the roadmap for future improvements.
. Provided leadership in the implementation of a Computer Maintenance
Management System (MP2 to Datastream 7i) to manage
work orders, PM's, parts inventory, purchasing, and asset management.
Alcan Pharmaceutical Packaging/Wheaton Plastics Des Plaines, IL
July 2002 - Nov 2003
Wheaton Plastics Division a $600M manufacturer of plastic bottles for the
Pharmaceutical industry.
Plant Engineering Manager
Managed activities for cost reduction initiatives, as well as Maintenance,
Engineering, Facilities and Mold Shop.
. Developed and implemented a 13 step strategic maintenance plan for
Alcan's pharmaceutical bottle plant. Plan ranged from Philosophical
and Theoretical shifts, Change Management, Asset Management,
Preventative Maintenance, and Accountability, while implementing a new
Computerized Maintenance Management System.
. Lead Six Sigma cost reduction project that reduced changeover times
from over 10 hours down to 2 hours resulting in a cost
savings/avoidance of over $800k.
. Project Manager for the consolidation of 3 North American facilities
including Puerto Rico expansion.
Knowles Electronics Itasca, IL 2001 - 2002
A $280M manufacturer of transducers for the hearing aide, telephony, and
automotive business.
Corporate Facilities Manager
Directed the activities for all Facility Maintenance and Corporate
Industrial Engineering activities worldwide.
. Realized over $2.5 million in savings by closing our integrated
circuit clean room facility located in Rolling Meadows, IL. Project
included transfer of product to other facilities, construction of new
clean room facility in China, and demolition of vacated manufacturing
operation in Illinois
. Developed project programming and planning parameters in conjunction
with outside design firm for the relocation of the corporate office to
a new site. Project included furniture design concepts, space layouts
and design, standardization of workstations, with an "open office"
design for improved communications.
. Directed activities and project plan for the demolition and the
remodeling of the corporate training facility. Project included the
design and completion of new lighting, ergonomic friendly workstations
and seating, computer stations, climate control system, and state of
the art audio and video systems.
. Provided engineering and design support for the relocation of the
Engineering and R&D departments from our Itasca facility to Elgin.
Project included using existing workstations and configuring modules
and panels to fit into much smaller work areas.
Rexam Medical Packaging (Formally Baxter Healthcare) Mundelein, IL 1984 -
2000
A $200M manufacturing and market leader in flexible medical packaging.
Facilities Project Manager 1998 - 2000
Directed high impact corporate projects. Responsible for Facilities and
Industrial Engineering projects including plant expansions and relocations.
. Realized $5 million in cost savings as Project Leader who consolidated 5
North American facilities into 3 "Centers of Excellence" including a JV
in Mexico. All ISO, cGMP's and FDA regulations were maintained in this
effort.
. Achieved over $800k in savings by managing the activities of relocating a
blown film and slitting process from our Minnesota facility to Illinois.
Project was transparent to our customers with no order fulfillment
issues.
. Achieved over $300k in savings by designing and executing the Divisional
Headquarters relocation from a leased facility, to the Mundelein
manufacturing facility. Project included space layouts, contractor
evaluation and selection, office design, and construction management.
. Managed joint 6 Sigma project with Johnson & Johnson to improve the
overall cycle time of product flow through the manufacturing process. By
using statistical tools such as design of experiments, multi-vari
analysis, and FMEA, cycle time was reduced from 8 weeks to less than 2
weeks.
Maintenance Manager 1995 - 1998
Directed the daily activities of a 25-person maintenance department
including machine shop, facilities, and numerous outside vendors.
. Reduced energy cost by $250k by implementing the facility's Computerized
Energy Management System (building controls) for HVAC, chiller systems,
lighting, and air compressors.
. Analyzed, selected, and implemented the CMMS Maintenance System
(Datastream MP2) which reduced inventory cost by $300k. The system also
created a "paperless" work order system, and improved overall maintenance
measurements and contributions to the organization.
. Reduced equipment failures and downtime by 75% by designing and directing
the activities of our "Maintenance 2000" program. This project integrated
the maintenance function with the production activities, which created a
joint ownership of equipment.
. Coordinated the installation of over 800 tons of new HVAC equipment,
cooling towers, chiller systems, and associated pumps and controls.
Senior Industrial Engineer, Staff Industrial Engineer
1984 - 1995
Managed the design and development of manufacturing process, capital
program, and process validations.
. Executed the re-layout of the facility into working cells as opposed to
the traditional machine clusters. This effort enabled the facility to
achieve "Continuous Flow Manufacturing" which reduced inventory and floor
space by 20%.
. Provided internal support by budgeting and management of the capital
program. Average annual budget of over 5 million dollars.
Education
Bachelor of Science in Industrial Engineering
1979
Industrial Engineering College of Chicago
Professional Training and Certifications
DePaul University University of Michigan
Business School
-Certification Program in Project Management-Nov 1999 -World Class
Manufacturing Certification
Certified Six Sigma Black Belt-June 1999 University of
Wisconsin
-Six Sigma Breakthrough Technologies -World Class
Maintenance
Computer Skills
-AutoCAD, Lotus Notes, Microsoft Word, Microsoft Excel, Microsoft Access,
Microsoft Project, SAP, Oracle,
-Microsoft PowerPoint, Datastream MP2, and 7i Maintenance Software