Maintenance Engineer
Resume:
LEON D. REED - CMRP
********@********.***
POSITION:
Reliability Engineering
EDUCATION:
Purdue University - Bachelor of Science Degree
Mechanical Engineering Technology, Honor Graduate - 3.52/4.00 GPA
Purdue University - Associate of Applied Science
Mechanical Technology, Honor Graduate - 3.56/4.00 GPA
Motorola University - Certified Six Sigma Green Belt
Three Phase Certification - 59/60 Score
INTRODUCTION:
Mr. Reed has over 20 years experience successfully designing, implementing
and managing industrial maintenance, plant engineering and reliability
programs and departments. Demonstrated strengths in Reliability Engineering
and management are the development, implementation, and application of
proven Proactive Asset Management (PAM) strategies and technologies using
strategic business models for Reliability and Operational Excellence.
Overall successes resulting in cost reductions, waste elimination,
variation reduction, standardization, improved equipment uptime, and
greatly improved plant, facility and process reliability are demonstrated
achievements. Associated successes includes statistical and analytical
control for sustainability and continuous improvement through data mining
for metrics, scorecards, Pareto Analysis, Key Performance Indicators (KPI),
and Root Cause Failure Analysis (RCFA).
Demonstrated strengths during extensive and successful process
implementations include:
Proactive Asset Management Validation/Startup/Commissioning
Implementation
Root Cause Failure Analysis (RCFA) Reliability Centered Maintenance (RCM
II)
Work Process Control and Management Planning and Scheduling
(WPC)
Reliability Centered Operations Standard Operating Procedures (SOP)
(RCO)
Project Management PM / PdM Optimization (PMO)
Facility/Equipment Asset Hierarchy 5-S Implementation
Change Management Processes (MOC) Failure Mode Effect Analysis (FMEA)
Computerized Maintenance Management Best Practices Implementation to Key
Systems (CMMS) and Implementation Elements of Reliability Excellence
Business Model
Master Equipment/Asset List (MEL) Spare-parts Inventory Optimization
Organizational/Reliability Gap Bill-Of-Materials (BOM) Development
Assessments
Predictive (PdM) Maintenance Total Productive Maintenance and
Technologies Program Implementation Improvement Strategies (TPM/Lean)
Reliability Centered Lubrication Cost Analysis and Capital Planning
(RCL)
Equipment Criticality/Risk Contractor & Supplier Management
Assessments
Statistical Reliability Control and Construction Management/Plant
Sustainability Engineering
Six Sigma Improvement Strategies Employee/Craft Job Specific Training
Failure Reporting Analysis and Cost Reporting Analysis and
Corrective Action Systems (FRACAS) Maintenance Mitigation
Wiebull Analysis - Monte Carlo (CRAMM)
Simulation Plant and Facility Engineering
Management
EXPERIENCE:
Senior Reliability Engineer, Consultant - Petrochemical
British Petroleum 2009 -2010, TRS/Fluor Enterprises
. Performed equipment and system walk downs for asset identification,
install verification, master equipment list, location tagging and
redlining P&IDs and AF&ID's for gas, diesel ethanol and fuel additive
storage facilities
. Developed location and equipment hierarchies for MAXIMO CMMS data input
for oil rigs, chemical refineries, gas and fuel terminals, process pipe
systems, tank farms, pig traps and distribution metering systems
. Performed quality upgrade remediation for obsolete engineering
documentation for offshore oil rigs, chemical refineries, tank farms, gas
terminals, process pipe systems, pig traps and distribution metering
systems. Included assimilating and editing field walk down equipment
data, redlined P&ID prints, manufacturer's data, existing CMMS data and
existing engineering documents.
. Collaborated with site petrochemical engineers, technicians and SME's for
investigative research for corrective action on process operations,
distribution routing and control of product delivery with respect to
P&ID's and documentation
Senior Reliability Engineer, Consultant - Steel Manufacturing
ArcelorMittal Steel, 2008 - TRS/Fluor Enterprises
. Analyzed site Maintenance Assessment/Audit of current state reliability
for gap analysis to jump start reliability and proactive maintenance
opportunities
. Developed new Root Cause Failure Analysis (RCFA) program with seamless
Failure Reporting Analysis and Corrective Action System (FRACAS) for
continuous improvement and sustainability
. Implemented and facilitated new group RCFA investigations with
stakeholders and cross functional teams including team building with
Ishakawa diagrams, Five Whys and Fault Tree Analysis methods for
determining root cause
. Used Tabware CMMS system to analyze equipment failure data, PM/PdM
strategies, work order history and schedule non-compliance for
contributing factor analysis to catastrophic failures
. Investigated Automatic Delay Reporting (ADR) system and Delay Action
System (DAS) for compiling total process downtime for cost evaluation of
catastrophic failures and cost avoidance for Corrective Action
Recommendations (CARS)
. Included strategies such as FMEA generated PM's, Predictive Maintenance
such as Oil Analysis, IR Scans, Motor Analysis, Vibration Analysis,
Ultrasound and Laser Alignment/Leveling and Reliability Based Lubrication
were recommended for CARS
. Recommended foundational processes and best practices of key elements to
asset management for reliability to be implemented and gaps to be filled
for acquiring a sustained Proactive Asset Reliability program and an
organizational transformation to a reliability culture
Senior Reliability Engineer, Consultant - Biotechnology
Eli Lilly Company, 2007-2008 - Crew Technical Services
. Assisted engineering departments of a major GMP pharmaceutical research
and development bio-tech facility to identify and perform overall stop
gap measures and quality upgrades from current state assessment to
improve total maintenance, reliability, validation, and engineering
documentation.
. Planned and performed quality upgrade, validation, commissioning and
Reliability Centered Maintenance (RCM) projects to GMP facility equipment
and utility systems such as pumped water systems (WBSO, DI, WFI,
Purified, Chilled, Glycol), compressed air, equipment air, breathing air,
HVAC, steam, rotating equipment, laboratory equipment, instruments and
devices compliant to all regulatory requirements and IQ/OQ/PQ protocols
. Performed asset delivery and RCM protocols such as asset identification,
asset location hierarchies, equipment criticality assessments, FMEA's,
optimized PM/PdM maintenance procedures, mechanical job task analysis,
job plans, print walk downs and redlining prints (P&ID's, AF&ID's),
maintenance schedules, strategic spare parts for MRO and CMMS (MAXIMO)
data input for capital projects or existing quality upgrade remediation
. Performed, assisted and documented validation and commissioning adhering
to the Validation Master Plan (VMP, SVMP) and Commissioning Test
protocols including Impact Assessments (ISPE), Design Qualifications to
User Requirements, Install and Operational Qualifications, Performance
Qualifications (IQ/OQ/PQ) with Test and Release verification (FAT's,
SAT's)
. Developed instrument and lab equipment calibration and testing SOP's
(Standard Operating Procedures) included into RCM optimized maintenance
strategies, PM/PdM routes, lubrication schedules and routes, validation
and commissioning documentation, and CMMS (MAXIMO) data input
. Performed monthly metrics reports and Statistical Reliability Analysis
using MTTR, MTBF, equipment uptime, reactive failures, failure cost, PM
compliance, etc. with data harvested from CMMS system
. Investigated and processed incidents, failures and deviations with
proposed corrective actions using Root Cause Analysis (RCA), Trackwise
and CAPA systems.
. Established a comprehensive predictive maintenance program (PdM) for a
newly constructed research laboratory facility including Oil Analysis,
Vibration Analysis, Motor Analysis, Ultrasound, and Infrared Thermography
Engineering Manager, Reliability and Maintenance Department -
Pharmaceutical
Eli Lilly Company, 2004-2007 - Jones Lang LaSalle
. Implemented and managed a new Reliability Engineering Department adhering
to strategic business plan, for standardizing and improving facilities
maintenance of over 100 pharmaceutical administration, laboratory,
research, aviation and office park buildings at six locations for five
maintenance departments of a large multi-national pharmaceutical
corporation
. Developed and implemented a large comprehensive Asset Reliability
Excellence Management program which included Proactive Asset Management
(PAM), Reliability Centered Maintenance (RCM), Root Cause Analysis (RCA)
and Total Productive Maintenance (TPM) incorporating a defined
Maintenance Management Model for Reliability Excellence built with
benchmarked best practices
. Performed leadership role in creating and communicating Reliability
vision, defining mission, acquiring robust executive commitment and
assigning roles, goals and objectives to achieving a proactive culture
change
. Responsible for RCM prescribed planned maintenance activities of five
maintenance departments on over 5000 pieces of equipment or building
systems including preventative and predictive maintenance
. Led development and implementation of the Maintenance Management Model
for Reliability Excellence which included implementing benchmarked key
elements of reliability methods using people, processes and technologies
while achieving sustainability and continuous improvement
. Developed and managed implementation of asset identification, asset
location hierarchies, commissioning, equipment criticality assessments,
FMEA's, optimized maintenance and PdM strategies and procedures, work
management processes, planning and scheduling, spare part inventory
optimization, CMMS optimization, key performance metrics and scorecards
(KPI's), bad actor reports, Root Cause Analysis (RCA), continuous
improvement and sustainability
. Developed data driven cost analysis methods and maintenance accounting
programs for Statistical Reliability Control (SRC) and Cost Reporting
Analysis for Maintenance Mitigation (CRAMM) utilizing performance metrics
such as MTBF, MTTR, uptime, reactive failures, failure costs, Pareto
Analysis etc. to identify most problematic units or activities to
optimize reliability and drive needed capital expenditures precisely
. Established predictive maintenance (PdM) and condition monitoring
programs Oil Analysis, Vibration Analysis, Motor Analysis, Ultrasound,
and Infrared Thermography.
. Directed, planned and supervised reliability engineering projects with
managers, engineers, supervisors and planner/schedulers in a team work,
group synergy environment to meld a Reliability Excellence roadmap into
hard copy details of scope, schedule and budgets
. Directed and led large comprehensive MAXIMO CMMS remediation project for
conversion from MAXIMO 4.1 to MAXIMO Enterprise Systems (MXES) in over
100 Admin, Laboratory and Office park buildings at six different sites
for five maintenance departments.
. Co-led Six Sigma Elevator Reliability project for over 200 elevators in
105 buildings. Project was nominated and runner-up for a national
engineering award
. Co-developed large server based Asset Enterprise Management database
computer system (RAMPP) with capabilities for electronic interactive RCM2
FMEA team development of maintenance strategies and retrieval of
equipment manuals, machine prints, Lockout/Tag out procedures (LOTO),
schematics and prints
Project Manager, Senior Reliability Engineer - Pharmaceutical
Eli Lilly Company, 2004 - Global Knowledge Management
. Managed Proactive Asset Management (PAM) development teams for delivery,
validation and commissioning protocols with IQ/OQ/PQ documentation,
commissioning and start up of new pharmaceutical and laboratory equipment
in FDA regulated GMP facilities utilizing Reliability Centered
Maintenance (RCM) methodologies
. Included Master Equipment List (MEL), Equipment Criticality and Risk
Analysis (FMECA), Failure Modes and Effect Analysis (FMEA), Mechanical
Integrity (MI), strategic spare parts (BOM's, MRO), maintenance
procedures, job plans, PM's and Predictive Maintenance
. Coordinated and managed data assimilation for loading into computerized
maintenance management systems (CMMS-MAXIMO) for coordinated Planning and
Scheduling after new equipment commissioning
. Monitored project according to tasks and subtasks assignments to
achieving project scope and milestones according to timelines, deadlines
and budgeted resources
. Negotiated new projects and writing proposals quantifying project scope,
schedules, budgets and resources
. Interacted with all GMP project contractors and owners to ensure proper
documentation, execution and flow of data delivery, right information,
equipment installation, validation for commissioning and equipment start-
up including P & ID and AF & ID verification, RFQ, RFP, RV. IV, Impact,
IQ/OQ/PQ, FAT's, SAT's Criticality, FMEA's, Tolerance Specs, Set Points,
SOP's, PM/PdM's and CMMS data input
Senior Reliability Engineer - Pharmaceutical
Eli Lilly Company and DSM Biologics Montreal, 2003-2004 - Global Knowledge
Management
. Implemented Maintenance and Reliability Excellence programs using RCM
with best practices to dysfunctional maintenance organizations while
performing current state assessments, gap analysis, future state
objectives, critical paths and CMMS (MAXIMO) implementation
. Performed equipment and system walk downs for asset identification,
install verification, master equipment list, location tagging, redlining
PF&IDs and developed location equipment hierarchies for MAXIMO CMMS data
input
. Assisted Validation Engineer with documenting or performing RV, IV,
IQ/OQ/PQ, FAT's and SAT's
. Performed location equipment criticality assessments (FMECA) for risk,
consequence and resource planning
. Performed RCM Failure Mode and Effects Analysis (FMEA) for optimized
maintenance strategy development and procedures on critical equipment
. Established and scheduled predictive maintenance programs (PdM) and
scheduled route for Oil Analysis, Vibration Analysis, Motor Analysis,
Ultrasound, and Infrared Thermography
. Developed RCM maintenance strategies, job plans, PM schedules, strategic
spare parts, lubrication and lube routes
. Developed lab equipment and instrument calibration and testing SOP's
from RCM optimized maintenance strategies
. Utilized CMMS system (MAXIMO) for planned maintenance work orders,
corrective maintenance, reactive maintenance and equipment reliability as
well as writing PM, Location and Equipment Data Entry forms for MAXIMO
. Established and administered benchmarked best practices for maintenance
department compliance in all key areas such as work order management,
planning and scheduling, PM/PdM, CMMS, spare parts, training, performance
measurement, qualification or commissioning and mechanical integrity
. Performed Root Cause Analysis (RCA), Failure Reporting Analysis and
Corrective Action (FRACAS)
Utility / Plant Engineer - Biochemical
Eli Lilly Company, 2002-2003 - Kelly Technical Services
. Responsible for plant utility system projects at large GMP pharmaceutical
company such as glycol, water, steam, air and HVAC involving chillers,
air dryers, compressors, pumps, tanks and tank farms, HVAC, heat
exchangers, PRV's, PSV's expansion tanks, BFP's, flow valves, etc.
. Planned and managed large scale GMP and non-GMP utility and biochemical
facility capital projects and oversaw FDA readiness validation,
commissioning and documentation of biochemical plant utility systems,
instruments and components
. Prepared change control documents with prescribed and implemented
corrective action items for remediation
. Developed RV/IV and IQ/OQ/PQ documents for validation and commissioning
activity
. Utilized CMMS system (MAXIMO) for planned maintenance work orders,
corrective maintenance and equipment reliability as well as writing PM
Data Entry forms for MAXIMO data input
. Performed equipment criticality assessments (FMECA) and Failure Mode and
Effect Analysis (FMEA) while developing maintenance plans, procedures and
strategies for critical utilities pharmaceutical processes and equipment
. Developed lockout/tagout (LO/TO) procedures and maintenance procedures
for GMP utility equipment and systems
Capacity Assurance (Reliability) Coordinator - Automotive
Indianapolis Metal Center, 1998-2002 - General Motors Corporation
. Managed and maintained a large reliability based preventive/predictive
maintenance program for manufacturing operations of a large automotive
stamping and assembly manufacturing facility including planning and
scheduling.
. Collected and analyzed root cause failure and effect data, maintenance
schedules and safety requirements to develop, plan and schedule
corrective, preventive or predictive maintenance procedures
. Developed and prescribed predictive maintenance procedures such as
Ultrasound, Motor Current Analysis, Infrared Thermography, Vibration
Analysis, Oil Analysis and Laser Alignment
. Determined appropriate failure rates, maintenance strategies,
frequencies, job plans, spare parts and methods of repair for material
handling equipment, utilities and automotive manufacturing lines
. Operated and maintained a computerized maintenance management system
(CMMS), (MAXIMO)
. Performed maintainable asset identification, equipment criticality
assessments, location hierarchies and FMEA's of new equipment into MAXIMO
while creating optimized PM/PdM masters, spare parts and frequency data.
. Assessed and evaluated equipment, systems and components to implement
controls, signage and maintenance procedures to improve reliability and
maintainability to maximize manufacturing life cycles while maintaining
repeatable product quality
. Practiced asset management through continuous improvement from
Reliability Centered Maintenance (RCM)
Previous Career Positions, Other - Automotive
Indianapolis Metal Center - General Motors Corporation
. Spare Parts and Material Expeditor - Buyer
. Plant Engineer, Manufacturing Engineer
. Skilled Trades Maintenance Supervisor
. Technical Trainer, Instructor, Course Developer and Training Coordinator
- Skilled Trades
CERTIFICATIONS
. Certified Maintenance and Reliability Professional (CMRP), SMRP
. Certified Six Sigma Green Belt - Motorola University, Schaumburg,
Illinois
. Completion - RCM2, Reliability Centered Maintenance - Strategic
Technologies (Aladon), Pittsburgh, Pennsylvania
. Completion - Weibull Analysis, Barringer and Associates, Eli Lilly,
Indianapolis, Indiana
. Certified Lube Technician - Eli Lilly, Indianapolis, Indiana
. Certified MAXIMO Training - MRO, General Motors, Dearborn Michigan
. Certified Capacity Assurance Coordinator - General Motors, Dearborn
Michigan
. Certified Training Consultant - Ball State University
. Certified Professional Trainer - GM Corporate Training, Detroit, Michigan
. Certified Welder, ASME Section IX, Hobart Welding College, Troy Ohio
. Certified Millwright Journeyman - GM Truck and Bus, Indianapolis, Indiana
. Certified FEMA Incident Command Training, ICS - 100, 200, New Orleans,
Louisiana
HONORS AND ACTIVITIES
. Member - Vice Chairman, Indiana Chapter, Society of Maintenance and
Reliability Professionals (SMRP) 2008, 2009
. Presenter - SMRP Indy Con 2009 Maintenance & Reliability Conference,
Lilly MQ Learning Center, Indianapolis, IN
. Graduate With Distinction - BS degree, Purdue University
. Graduate With Distinction - AAS Degree, Purdue University
. Dean's List Awards - Purdue University
. Tau Alpha PI Academic Honor Award - National Honor Society for
Engineering and Technology
. Award Nomination - DaVinci Award for Innovation - Six Sigma Elevator
Reliability, 2006
. Outstanding Trainer Award - Hobart Welding College, Troy Ohio
. Lecturer - Department of Supervision, Purdue University
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