Expert Manager and Engineer with applied knowledge in: TQM, Six Sigma

Problem Solving, Lean Manufacturing, TPM, Supervision, Process Control,

Engineering Design, Budget Control, Mentoring, Environmental Compliance,

Safety, PSM, and Project Management.

EXPERIENCE

Sr. Process Engineer, Facility Engineering, SUMCO Phoenix, Maineville, Ohio

December 2004 to Present

Responsible Engineer for Facility Support Systems at a Semiconductor Wafer

Production Site that includes: EPI reactor exhaust treatment; Hydrogen gas

recovery; high purity - concentrated Hydrofluoric, Hydrochloric, and Nitric

Acid distribution; Hydrogen Chloride Gas; air emission scrubbers (including

NOX); ultra high purity water; ultra high purity cryogenic gases;

compressed air; wastewater neutralization; Arsenic wastewater pretreatment.

EPI exhaust treatment processes covered by Process Safety Management

include: flammable gas collection and transport, Trichlorosilane

condensation, Hydrogen Chloride gas neutralization, bulk tank storage, and

truck loading. Hydrogen recovery processes include Hydrogen gas

compression, impurity removal of CO2, O2, H20, and N2 to less than 1 ppm.

PSM support includes process hazard assessments, management of change

review, pressure vessel and safety relief systems, equipment specification,

mechanical integrity, operation work procedures, and training.

Root cause problem solving cost reductions: cryogenic Nitrogen gas reuse

($390K/yr), compressed air optimization ($135K/yr), Hydrogen compressor

MTBF rate increase from 0.3 yr to > 3.0 yr ($106K/yr), vacuum pump water

Silica control ($111K/yr), ultra high purity water equipment performance

($109K/yr), and Tri-Chlorosilane condenser clogging MTBF rate increase from

1 yr to > 2 yr ($55K/yr).

Principal Chemical Engineer on the vacuum pump water system's Silica

control system that included design and implementation of an Arsenic

wastewater pretreatment system based on Silica solubility.

Group Leader, Facility Engineering, Environmental, & Safety, Thomson Inc,

Marion, Indiana

October 1999 to December 2004

Provided Facility Engineering, Environmental, and Safety Support at a 1,300-

employee, 1MM sq ft facility manufacturing color TV picture tubes.

Facility engineering efforts included engineering design, capital funding,

$20MM/yr utility group budget variance analysis, and project management.

Facility Utility Systems included: 100K lb/hr of 100 psi steam, 5K tons of

chilled water, 14K scfm of 100 psi compressed air, 1100 gpm of Deionized

water, 7K tons of cooling tower condenser water, bulk cryogenic gases, air

emission scrubbers (including VOC thermal oxidizer), and 500K sq ft of

temperature and humidity controlled, semi-clean room production area.

Facility system improvement cost savings: compressed air optimization

($315K/yr), HVAC 200 ton chilled water reduction ($192K/yr), wastewater

system cleaning ($68K/yr), chilled water system pressurization ($30K/yr),

and CMMS-Preventive Maintenance program implementation.

Responsible Charge Operator of a 2.0 mgd wastewater pretreatment facility

removing Lead, Zinc, Chromium, and Fluoride. Managed 4 hourly operators

covering a 24x7 Operation with a $1MM/yr operational budget. Optimization

generated $255K/yr in cost savings.

In 8/2002, Environmental & Safety Representative Responsibilities were

added. Behavior based safety efforts led to a 2003 Incident Rate

reduction of 35%, and a $505K/yr Workman Comp cost reduction.

Environmental Engineering Specialist, Philips Display Components, Ottawa,

Ohio

August 1991 to October 1999

Responsibilities were focused around Environmental Compliance and Facility

Chemical Engineering Support at a 1500 employee, 1MM sq ft facility

manufacturing color TV picture tubes. The production environmental

statistics included: 30 hazardous waste streams totaling over 2.5MM lbs/yr

shipped, 5MM lbs/yr of recycled glass shipped, 0.5 mgd wastewater

pretreatment, Title V Air permit with over 200 listed sources, 1K MSDS

documents, and 10 SARA Form R reportable chemicals.

Management Responsibilities included supervision of a 7 person salaried

environmental group with a $2.1MM annual budget. The department operated a

24x7 wastewater pretreatment facility. Improvement cost savings included:

hazardous waste cost ($500K/yr), production DI water reuse or reductions

($194K/yr), reduced actual VOC emissions by 193 tons/yr, and Nitric Acid

waste by 750 tons/yr. Managed $13.5MM in departmental projects.

Production Environmental Responsibilities included: wastewater treatment,

hazardous waste management, air pollution, stormwater, spill response,

vendor liability audits, water recycling, pollution prevention, and

underground storage tank programs. Was technical lead in resolving a 1989

OEPA lawsuit resulting in a $1.3MM penalty from a $6.4MM original demand,

with $0.8MM in allowed SEPs. Solved 13 year-old Total Chrome NPDES

Discharge Violation Concern using existing 1986 wwt equipment.

Divisional Environmental Responsibilities included the design, agency

negotiation, and implementation of RCRA Part A Interim Area Closure and

Corrective Action Programs, at two manufacturing sites, with $3.8MM in

Remediation Costs.

Facility Design Engineering Responsibilities included: bulk chemical

storage and delivery systems, DI water generation, wastewater collection

and pumping systems, air pollution control devices (acid scrubbers and

thermal oxidizers), facility-wide water balance and reuse analysis, and

advanced filtration systems for water reuse.

During 1995 - 1996, a $100MM, brown-field, Jumbo CRT Production Facility

was designed and constructed within 18 months implementing both imported

and locally designed production technology. Became Project's Principal

Chemical Engineer covering: the FEED Study, chemical mass and energy

balance, emission modeling, and mentoring on P&IDs, process control

methods, and general equipment design.

Project Engineer, Weyerhaeuser Personal Care Products, Bowling Green, KY

January 1989 to August 1991

Responsibilities were focused around a $40MM, 300 fpm continuous web

process creating Super Absorbent Powder (SAP) for the diaper industry. The

production line utilized an electron beam to convert Acrylic Acid and

Potassium Hydroxide into SAP.

Responsibilities included: R&D process scaling, P&ID development, equipment

sizing, piping design, equipment/pipe/heat trace/insulation specifications,

construction contractor review, process startup, process operation manuals

development, and employee process training. Was responsible for the

construction and startup of a $5MM chemical mixing facility, cooling water

systems, and monomer delivery systems.

In 10/1990, environmental program responsibilities were added. Waste

vendor site assessment program rated excellent by corporate auditors.

EDUCATION AND PROFESSIONAL ACHIEVEMENTS

Degree: B.S. Chemical Engineering, College of Engineering, University of

Cincinnati

Professional Engineering Licenses: Kentucky and Ohio.

Indiana Industrial Waste Water Treatment Operator Class D Certificate.

OSHA 1910.120 and NFPA Hazardous Material Incident Response, Trainer Level.

OSHA 1910 Outreach Consultant Trainer for 30 & 10 hr Train the Trainer

Courses

Working Knowledge Areas:

Management: Goals Based, KPI, EBITDA, Scorecards, Budgeting, Variance

Analysis, Coaching, Supervision, Change Leader, Self-Directed Team

Facilitation, Benchmarking, Mentoring, Dashboards and Scorecards.

Six Sigma - Lean - Quality: TQM, ISO/TS16949, Process Capability, SPC, X-

Bar & R Charts, Five S, Kaizen, Statistical & Team Problem Solving, FMEA,

Plan-Do-Check-Act, DMAIC, Cause & Effect, and Pull System.

Total Productive Maintenance: OEE, Quick Change-Over, Preventative,

Predictive, Autonomous, CLAIR, and CMMS

Safety: Behavior Based, DuPont STOP, Training, PSM, Mechanical Integrity,

Accident Investigation, Hazard Analysis, OHSAS 18001, Risk Ranking, LOP,

and SIL.

Environmental: Title V Air Permit, NSR, PSD, Stack Testing, NPDES

Discharge & Pretreatment, Reporting, Hazardous Waste, RCRA Subpart AA, BB,

& CC, SPCC, Spill Response, Underground Storage Tanks, Part A Closure and

Corrective Actions, ISO14001, and Wetlands.

Engineering - Project Management: Stage Gate, ROI, Capital Request, Cash

Flow, Timeline Critical Path, Resource Balancing, M&E Balances, Equipment &

Process Design, R&D Scaling and Development, Process Industry Practices,

ISA Instrumentation Practices, and Pressure Vessel & Safety Device

Practices.

Computer Programs: Microsoft Word, Outlook, Excel, Powerpoint, Project, and

Access Database programs, ACAD, Autoplant Designer, Engineer's Aide SINET,

Maximo and SAP CMMS, OSHALog, IPRAX Safety CDROM Training, Adobe Acrobat,

and SAP accounting programs.

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