Manager Engineer

John McKay

**** ******* ***** / ****, **, *****

714-***-**** / ********@*****.***

Plant Manager / Operations Manager

Executive Summary

. Accomplished Operations and Plant Manager skilled in creating culture

of continual improvement.

. Unique blend of motivation leadership, technical problem solving and

business skills for long-term success.

. Provides focus for vision and direction, prioritizes capital spend and

operating procedures, and drives results.

Leadership

. Leader of manufacturing Plant and Operations of 30 full time and 300

union employees.

. Led safety efforts that eliminated recordable injuries during

remainder of 4-year tenure.

. Led multi-disciplined team to improve overall equipment effectiveness,

increased production 11%.

. Sponsored mill energy and water team that reduced water use 25% and

total energy 12%.

. Worked on training and scheduling plans to reduce overtime and call

time >50% over 3 years.

Project Management

. Machine rebuild startup-$12MM

. Complete paper machine dust system-$2.5MM

. Automatic pulp bale dewiring and pulper-$7MM

. Twin felted Paper machine conversion to single-$0.8 MM

. Fiber costs operating strategy-$2MM/year reduction

Strengths

. Applying Technology

. Root Cause Analysis

. Lean Manufacturing

. Team Empowerment

. Environment Planning

. Personnel Accountability

. Resource Management

. Productivity Improvement

. Leading Reliability Initiatives

. Capital Project Management

. Data-Based Decision Making

. Goal Setting with Clear Vision

. Safety Improvement Initiatives

. Operational Excellence Principles

. Continuous Improvement Culture

. Quality Investigation & Improvement

. Koch's Philosophy-Market Based Management

Key Career Accomplishments

. Key member of Safety Management System eliminating recordable

incidents in department for 4 consecutive years. Led Safety

Improvements initiatives including creating safety culture,

reorganizing safety coordinators' roles, risk assessment, and

reorganizing safety committees with clear

expectations/accountabilities.

. Leader of mill Reliability Team that won corporate-wide award for

having best reliability results out of 13 mills. Improvements allowed

successful bid on large new contract. Achieved cost savings of:

o Allocated resources for 25% water and 12% energy reduction (steam,

electricity, and natural gas).

o Worked with chemical vendor and process engineers to run trials to

make softer product that allowed more recycled fiber to be used

while maintaining quality specifications.

o Teamed with contract negotiating committee to change rules around

call time, and built new training plan.

o Worked with union leadership to eliminate 1 position (4 jobs) after

capital automation project.

. Built competitive secondary fiber business reducing paper

manufacturing costs and saving plant from closure. Worked with

controller to determine impact of shutting plant including analysis of

fixed and variable costs. Met with customers to establish

requirements. Worked with operators to set up new operating strategy

and centerlines to greatly improve pulp quality. Set up pulp protected

pricing strategy, and cut costs via changing operation hours and

reducing headcount.

. Set strategy to reduce fixed costs and ensure product supply. Used

Lean Manufacturing Tools to create Strategy Deployment A3 document to

analyze problem and create hypothesis/action plans to improve

throughput. Conducted 4-Step Problem Solving sessions with engineers,

operators, and maintenance personnel to solve long term chronic

problems. Used Lean tools (Visual Management, SMED Workshops, Kaizen,

5S, and TPM) to make operating practices and strategies improvements.

Career Progression & Impact

Kimberly-Clark Corporation / Fullerton, CA / 2011 - Present

ENGINEERING TECHNICAL LEADER (2011 - Present)

. Lead multi-disciplined team at Lean manufacturing site (engineers,

operations, and maintenance) to improve overall equipment

effectiveness for world-class manufacturer of consumer products.

. Work with corporate staff to produce Lean documents for improvement

plans and provide guide paths for productivity increases; lead problem

solving efforts to resolve chronic problems.

. Employ Lean Manufacturing Principles e.g. A3 development, 4 step

problem solving, visual management and standard work.

John McKay

Executive Resume, Page 2

Kimberly Clark Corporation Engineering Technical Leader Continued:

Impact

> Led start-up tissue machine from $12MM rebuild.

> Improved productivity 11% by improving machine speed and reducing

major reliability events.

> Participated on safety leadership committee which reduced

recordable injuries from 8 to 2 in 1 year.

Georgia-Pacific / Halsey, OR / 2007 - 2011

$7B manufacturer of consumer tissue products; Halsey mill

produces consumer bathroom tissue and paper towels.

Progression as follows:

OPERATIONS MANAGER (2011)

. Continued to manage paper machines and secondary fiber plant while

adding 10 tissue and towel converting lines, additional 6 salaried

employees and 200 union employees.

. Oversaw multiple areas including paper production, recycled fiber

production and outside customers, safety, environment, and

reliability.

Impact

> Sponsored mill energy and water team that reduced water use 25% and

total energy 12%.

> Worked on innovative operating strategy to reduce fiber costs

$2MM/year.

> Team member that created Environmental Management System for

compliance/environmental excellence.

> Led Reliability Team in setting vision and action plans for mill

winning G-P Reliability Award.

PAPER & FIBER MANAGER (2007-2011)

. Managed 2 paper machines and secondary fiber plant; oversaw 6 salaried

and ~70 union employees.

. Took over Environmental, Quality and Technical Department, adding

additional 5 salaried employees.

. Led safety efforts for departments in area and ensured resources

allocated appropriate to potential risk.

. Member of Halsey Central Safety Committee and leader of Papermill and

Secondary Fiber Steering Teams.

. Work with production leader, union leadership and human resources to

settle contract grievances.

. Assume mill manager responsibilities during periods of vacation.

Impact

> Had 1 recordable injury in 2007 and -0- recordable injuries in

following 4 years as Manager.

> Led effort of 6% overall improvement in productivity of machine

uptime and production on 2 paper machines by metalizing Yankee

dryers and implementing use of ceramic creping doctors.

> Oversaw capital projects i.e.

o automatic pulp bale dewiring and pulper, $7MM project;

o complete paper machine dust system, $2.5MM;

o conversion of paper machine from twin felted to single felt, $0.8MM.

> Reduced crew size in paper mill by 1 employee per crew.

> Cut overtime/call time >50% during 3 year period optimizing

training and scheduling plans.

> Achieved continual improvement of production in both paper tons and

converting cases; assisted in development of premium tissue grade

on paper machine and converting to optimize production stream.

> Leader of mill's Reliability Team winning GP award for mill with

Best Reliability.

1 Kruger Tissue Products (Scott Paper Ltd.) / New Westminster, BC / 1996 -

2007

OPERATIONS MANAGER - PMs 1,2,3 (2006-2007)

. Managed 3 tissue paper machines, 6 salaried employees and 90 union

employees (during period of major crew and cost reduction measures).

Impact

> Reduced fiber costs $ 1.1MM/year initiating running paper machine

trials with different chemistries/pulp.

> Capital rebuild team member to install paper machine hood and

convert twin felted machine to single felt.

WESTERN PAPERMAKING TECHNOLOGY MANAGER (2004-2006)

. Performed trials on paper machines, including product development,

innovation, and cost reduction.

. Spent time in mills in England and Colombia to develop and implement

improvement plans, e.g. paper machine audits, headcount

rationalization, cost reduction plans, and reliability improvement

plans.

. Oversaw planning and performing pilot plant trials with paper machine

manufacturers in Sweden and Brazil.

Impact

> Assisted in developing 1st 3 ply Ultra product in Canadian market.

John McKay

Executive Resume, Page 3

Kruger Tissue Products Progression Continued:

SENIOR OPERATIONS ENGINEER PM4 (2000-2004)

. Optimized all aspects of critical paper machine; supervision of crew,

safety, production, costs, quality, uptime.

Impact

> Achieved annual savings of $0.75MM via developing innovative way of

mixing different fibers.

> Oversaw operations side of $2MM capital project to modernize dry

end of paper machine.

PAPER MILL SUPERVISOR (1997-2000)

. On-shift supervisor for 4 tissue paper machines and crew of 20 union

employees.

. Provide on-site leadership during off hours including emergency

response, spills, and staffing.

. Provide leadership on shift for safety, quality, environmental and

personnel issues.

Impact

> Optimized machine conditions to minimize costs and maximize

productivity.

PROCESS / ENVIRONMENTAL ENGINEER (1996-1997)

. Ensured Environmental Compliance for mill.

. Supervise 5 environmental technicians.

Impact

> Implemented/negotiated new waste water permit for mill with

government agency, including innovative way to monitor pH to ensure

compliance.

Prior Career Foundation

BASF Chemicals Canada /1993-1995

Technical Sales & Service Representative

. Provide sales and service to 13 paper mills across Western Canada.

. Chemical products included retention aid, defoamers, sizing agents,

and dyes.

. Gained experience in newsprint, fine paper, sack kraft and tissue

paper.

Arbokem Inc. / 1992-1993

Project Engineer

. Assisted in design of pilot non-wood pulp mill.

. Ran lab pulp trials using flax, hemp, and wheat as raw materials.

Professional Development

Education

. Bachelor of Applied Science - Chemical Engineering / University of

British Columbia, Vancouver, BC

Specialized Training

. Accountability

. Safety Initiatives

. Environmental

Management/Supervision

Instrumentation Loop Tuning

Capital Project Tracking

. Technical-Tissue Industry

. Chemical Product Safety (CPS)

. Candidate Selection & Compensation

. Lean Training - Kimberly Clark

. Management Training - Georgia Pacific

. Reliability - Lubrication, Laser Alignment, Predictive Maintenance,

Planning, Root Cause Analysis

Affiliations

. Member of Professional Engineers - British Columbia, 1992-2007

. Technical Association of Pulp & Paper Industry, 1994-2000

Competition

. Actively involved in marathon training and running.

Contact this candidate