Giorgio Girardi

* ******* *******

Old Saybrook, CT 06475

Mobile 401-***-****

Experience Summary

Extensive experience in process engineering, manufacturing, quality, safety, root cause analysis, waste reduction, capital projects with financial responsibility, equipment design, product design, start up operation, plant engineering, lean manufacturing, SPC, environmental compliance mostly in the chemical, mixing, coating, printing and web converting industry.

Worked on over 1 MM capital projects. Designed and built a mixing operation for coating fluids mixing and particle size control. Designed, installed and reduced to practice a paper and film coating line. These two projects were over 1 MM in capital spending. Wrote the PLC logic for the mixing operation and coating line.

Performed quality, safety and productivity audits, trained operators and manufacturing personnel and was constantly on the manufacturing floor offering advice and support.

Experience with slot die coating, knife coating, rod coating, roll coating and calendaring operation.

Experience with tension control, drive systems, web handling and PLC design.

Experience with UV fluid mixing, handling and coating.

Experience with converting machines such as Deacro, Dusenbery and Senn slitters.

Experience with roll packaging machines.

Experience with HVAC, chillers, cooling towers, fire systems and building automation, boilers, steam systems and water treatment.

Solid understanding of PLC and PLC logic design.

Managed a group of eight maintenance technicians and one mechanical engineer. Reduced and improved the maintenance work orders flow and cut down the work orders turnaround time by 25%.

Extensive experience with fluid filtration, filter systems including clean room application.

Ability to take products from R&D into the manufacturing floor.

Excellent people skills, team building and team management.

Worked on process yield improvements, root cause analysis, waste reduction and lean manufacturing projects.

Worked with customers, customer specifications and customer support. Reduced customer complaints by analyzing and reducing process variability.

Experience with ISO 9000 and 9001, unionized and non-unionized work force.

Professional Experience

May 2015 to December 2015. IPG, Columbia, SC Contract completed

Senior Engineer

Worked with two PRE extruders and improved the side feed operation from 12 side feed failures per week down to 1 per week. Set up a process downtime tracking system and defect analysis using Pareto Charts that led to the elimination of defects such as “Tear Outs” and “Roll Cleaning/Taping”. Participated in setting up and training of a new coating process for duct and masking tape production. Improved extruder side feed performance by evaluating and changing the raw material feed process.

December 1998 to May 2015. Arkwright Advanced Coating Fiskeville, RI (Plant Closed)

Plant Engineering Manager

Responsible for all plant engineering and related maintenance operations. Managed a department of eight trades and one mechanical engineer. Increased machine utilization time by 20%. Instituted preventive maintenance programs that improved machine and process reliability.

Designed and installed new coating line for paper and film coating. Dealt with environmental and safety issues and kept three solvent incinerators running at 98% efficiency to meet EPA and State regulations.

Designed, built and reduced to practice a coating fluid mixing and handling operation for solvent and water borne coatings production lines.

Worked on many projects to improve the coating and converting process in the plant. Reduced waste by 10% and reduced machine set up time by 30%.

1996 to 1998. Furon Company. Custom Coated Films, Paper and Fabrics Division. Worcester Massachusetts

Second Shift Manufacturing Manager

Lead the second shift Manufacturing, Quality Control and Maintenance operations. Set up shift performance metrics and improved second shift performance by 12%. Reviewed jobs requirements, including customer specifications and machine capabilities. Provided manufacturing personnel with the information and tools necessary to run each job successfully. Constantly helped people solving problems on the manufacturing floor by listening, getting involved and by promoting team work.

Senior Process/Quality Engineer

Led the Quality Department composed of three quality control technicians and one quality engineer. Reviewed customer requirements and updated all the quality procedures from customer requirements to returned goods. Worked with customers in solving product/process problems and matched job requirements to machine capabilities. Reduced customer returns by 8%.

1995 to 1996. Nashua Corporation. Specialty Coated Products Division. Merrimack, New Hampshire (Needed to change position due to 150 miles a day commute)

Senior Process Engineer/Team leader

Formed and lead a self supported work team for the carbonless and thermally activated paper coating operation. Reduced waste by 20%. Provided engineering support to customers and all team members. Ran the coating fluids making operation and implemented process improvements that lead to higher fluid quality and reduced waste.

1986 to 1995. Avery Dennison Corporation. Label Printing Operation. Framingham, Massachusetts (Plant Closed)

Quality Audit Manager

Managed eight quality auditors performing process/product audits for compliance to process, product and customer specifications. Introduced the team building concept and expanded it major company customers such as Proctor & Gamble and Sharing Plough.

Senior Process Engineer

Responsible for process improvements, yield improvements, cost reduction and SPC implementation. Reduced coated paper waste by 20%. Designed and installed a data acquisition system using Wonderware in the printing operation. Introduced and trained operators in the use of process control charts. Developed a universal defect standards book used by operators and customers in the printing operation.

Senior Quality Engineer

Team up with the quality manager to design and implement the Company Wide Quality Assurance Manual. Wrote all the applicable procedures and started the SPC concept in the coating and printing operation.

1981 to 1986. W.R. Grace. Emerson and Cuming Division. Manufacturer of Microwave Absorbers and Specialty Chemicals. Canton, Massachusetts

Engineering Supervisor

Supervised a five member product design engineering team. Reduced engineering turnaround time for customer quotes by 25%. Reduced the cost of molded products by 35%. Responsible for all engineering activities including generating customer quotes and supporting three manufacturing plants.

Technical Supervisor

Set up the Emerson and Cuming Quality Assurance System. Wrote the division Quality assurance Manual. Set up the quality system to meet the military standards MI 45208. Designed and manufactured a cover for the military Pershing II Nuclear Missile System under highest government clearance

1978 to 1981. Great American Chemical Corporation. Manufacturer of PVC resins and PVC blends. Fitchburg, Massachusetts (Plant Closed)

Process Engineer

Ran the pilot plant operation. Helped develop a PVC fire proof latex used to coat fire proof fabrics. Designed and installed reflux condensers on eight PVC reactors that reduced the total reaction time by30%. Worked on the PVC formulation blending and extrusion line. Purchased and installed a single screw extruder for extruding and pelletizing customized PVC compounds.

Education

Bachelor of Science in Chemical Engineering from the University Of Massachusetts at Lowell, MA. Completed 36 credits toward a Master of Science in Polymer/Plastic Engineering at the University of Massachusetts, Lowell, MA. Started thesis “Measure of Heat Transfer Coefficients” in Blown Film Extrusion in process to be completed.

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