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Project Manager Maintenance

Location:
Buffalo Grove, IL
Posted:
October 28, 2014

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Resume:

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



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