William R. Costa

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

Belvidere, IL 61008

815-***-****

abhyye@r.postjobfree.com

PROFILE

Plant Operations Manager - Project Manager - Engineering and Maintenance

Manager

Strong Technical and Plant Operations background includes over 18 years of

Engineering, Maintenance, and Operations Management experience, as well as

10 years in Capital Planning, Business Process Optimization, and Corporate

Project Management.

In-depth experience includes: ISO 9001:2008, LEAN Manufacturing, Kaizen,

Total Productive Maintenance (TPM), SPC; project planning, design,

development and execution; development of Long Range Plans to optimize

current operations and position company for expansion; budgeting, both

capital and operational expenses; performance analysis and improvement;

personnel development, training, and management.

Strong focus areas include streamlining of operations, improved process and

performance planning, and resource optimization. Consistently established

and enhanced processes and controls to provide timely, meaningful, and

pertinent manufacturing performance indicators to support a culture of

continuous improvement. Strategic thinker and planner with excellent

technical, analytical and communication skills. Experience includes 7 years

in Food and Beverages, 12 years in Ceramic Materials.

Strategic and Long Range Planning

Department Restructuring/Re-engineering

Turnaround Leadership

Project Planning/Development/Management

Budgeting/Forecasting/Control

LEAN Manufacturing and TPM

Cost Reduction/Optimization

Manufacturing Process Control/Optimization

Problem Identification/Analysis/Solution

PROFESSIONAL EXPERIENCE

Engineered Ceramics - Gilberts, IL Aug 2004 - Present

Engineered Ceramics is an ISO 9001:2008 manufacturer of industrial ceramics

with $7 million in sales.

Manufacturing Manager (Plant Manager)

Responsible for direction and management of production and plant

maintenance as well as capital project planning and execution. Areas of

responsibility include manufacturing/operations, facilities, utilities,

plant automation, purchasing, vendor management and EHS. Manage 30 direct

reports.

Results:

Adjusted kiln schedules to increase throughput by 4.8%. Implementation cost

$0.

Analyzed and modified the firing schedule for a key new product. The new

firing profile reduced scrap from 30% to 10%.

Reduced average Raw Material Inventory by 20% through careful planning and

forecasting which exceeded corporate goal of 15%.

Reduced overall fired scrap from 8% to 4%, a 50% reduction.

Oversaw implementation of new kiln automation and control package. This

resulted in a 20% reduction in natural gas use and virtually eliminated

kiln shutdowns.

Created a Predictive Maintenance System, and implemented a Kanban system

for stocking critical spares.

Currently phasing in TPM program.

Ipsen Ceramics - Pecatonica, IL Aug 1999 - July 2004

Ipsen Ceramics is a toll processor of industrial ceramics with $4 million

in sales.

Engineering Manager

Responsible for Engineering, R&D, Quality, and Training. Provided support

to Manufacturing Maintenance and IT. Duties included design and

implementation of capital projects, cost analysis, process optimization,

technical support for sales, and troubleshooting technical issues in the

plant.

Results:

Aided numerous customers in process and product development including an

environmentally friendly consumer product made from recycled glass.

Oversaw capital projects to add sizing and blending operations.

Renegotiated UAW labor contract on time and in budget.

Implemented MRP system for manufacturing.

Tetra Pak Plant Engineering - Vernon Hills, IL May 1993 - Aug 1999

Tetra Pak is a manufacturer of processing and packaging systems for liquid

food and beverages.

Project Engineer-Project Manager

Responsible for designing large-scale dairy, food and beverage processing

systems, which range in value from $5K to $3M. This included optimizing

customer production schedules, engineering calculations, component

selection, site management, and system start-up.

Results:

Worked and managed a variety of projects including a new plant for Ben and

Jerry's Ice Cream in St Albins, Vermont and a pilot plant for Tropicana in

Bradenton, FL.

Implemented an Integrated CAD system / components database which reduced

time to quote by over 10%.

EDUCATION

University of Illinois at Urbana-Champaign

Bachelor of Science, Ceramic Engineering

Illinois State Scholar

Wisconsin-Madison Department of Engineering Professional Development

Pumps and Process Pipping

Industrial Refrigeration

Certified trainer for Community Emergency Response Teams in Illinois

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