Project Manager Plant
Resume:
William R. Costa
Belvidere, IL 61008
******@****************.***
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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