Engineer Process
Resume:
PHILLIP L. GAIETTO
Clinton Township, MI 48038
Over 20 years experience regarding design, implementation, and support for
implementing / upgrading manufacturing and management systems. Results
oriented self starter with a proven ability to find hidden value by
streamlining operations and support processes to address changes in
internal and customer needs, via systems / personnel / materials
assessment, technology application, project management, personnel
development, and leadership.
CAREER OBJECTIVE: Leadership role within a highly adaptive, customer
driven organization that utilizes my skills and experience in implementing
technical change to increase profitability.
EDUCATION: MBA Belmont University, Nashville, TN December 1993
BSChE Ohio University, Athens, OH August 1986
KEY SKILLS:
Plant Management, Trainer: HS&E, SAP, MRP Forecasting &
Supervision Budgeting
Manufacturability Recipe / Methods Process Analysis,
Assessments Development Economics
Technology Transfer Equipment Specification Facility Design /
Build / Startup
Fill Line/Packaging Time Studies, Task DCS, Instrumentation,
Engineering Streamlining CAD
Quality Engineering / Maintenance Planning Warehouse Management
Statistics
EXPERIENCE:
Production Manager - 15 Million Pounds per year Hot Melt Adhesives Facility
Adhesive Systems, Inc. 14410 Woodrow Wilson, Detroit MI July
2004 to Present
. Responsible for weekly yields, manpower, utilities, order fulfillment
rates, quarterly inventories
for a 3 shift, 24 hour operation running 5-7 days per week,
union workforce
. Planned all process, labor, materials, supplies, and freight using
manual MRP system
. Developed Preplanning System for Raw Materials and Finished Goods:
Filled standard (>2wk) orders at 100% using order patterns, field
information, order predictions
Improved scheduling / process capability to fill orders with less
than 2 week leads to above 97%
Reduced Working Capital (Finished Goods and Raw Materials) by
$700,000
Streamlined Finished Goods Handling via staging shipments right off
packaging line
. Design / Implemented 10 Hour Staggered Shift Schedule, reducing
Overtime by 50%
. Developed / Maintained / Improved Mixing Instruction Sheets for all
Formulas
. Implemented plant improvement and material reclamation projects:
* 120,000 Lb. idle materials reclaim per year for three years
($150,000/yr).
* Designed and tied in $5000 box filling system, avoiding $125,000
capital investment
* Changed Process and Procurement methods to reduce rupture disk costs
by $5000/yr.
* Changed coolant system circuit to allow concurrent cutting on two
lines for double rates
* Developed Plant Expansion Proposal for 65% capacity increase using
existing equipment
Quality Engineer/Manufacturing Engineer/Process Set Up Operator - Liquid
Bottling Plant
Axios Staffing / KDM Engineering
Assigned to Bissell, Inc., Grand Rapids, MI December 2002 to
July 2004
. Quality Engineer:
* Process Economic Assessments using Accounting Software
* Batch Controls Recipe Management Using Controls Database
* Led Batching and Packaging Trials on new formulations from R&D
. Manufacturing Engineer:
* Batch System Recipe Development & Ingredient Handling Systems design,
pH/SG loop design
* Engineering for Bottle Fill Line and Pack Out Systems improvements
* Bill of Material Adjustments in Accounting Software
* Caustic Handling System Commissioning, Environmental Support
. Supervisor - Process Set Up:
* Supervised Upright Handle Assembly, Repack, and Chemical Packaging
Areas
* Automated Batch System Operator training / Supervision (Hands on
operation)
* Developed Graphical Layout and Instructions to speed Liquid Tote
Setup, eliminate errors
* Created Process Packs for Bottle Fill and Pack Line, increased First
Time Right by 20%
* Developed Filler Change Over parts handling methods, reducing change
time by 30-60%
Project Engineer - High Purity Solvents Manufacture
Honeywell - Burdick & Jackson Muskegon, MI March 2000 to August
2002
. $425K Glass Lined Tanks / Piping / Condenser Installation
* Developed Process System, Equipment Specs & Instrumentation (PIDs,
PFDs, etc.)
* Oversaw Contract Engineering and Construction - structural steel,
controls, etc.
* Saved $35K by retrofitting idle glass tankage
. $175K Glass Bottle Filling Line Retrofit: Fill / Cap / Label / Package
Flammable Solvents
. $45K Bottle Dosing System with Reservoir to increase fill accuracy to
specifications
. Obtained and installed $2,500 desiccator to eliminate need for $125K
drying tower project
. Installed piping changes to allow concurrent package filling without
major engineering studies
. Installed $8,500 pump/pipe system, eliminating need for $65,000 mixing
system project
. Used SAP Modules to track projects, provided training during SAP
startup
Process Engineer - Paint Pigment Manufacture
Millennium Inorganic Chemicals, Ashtabula, Ohio August 1997 to
January 2000
. Process engineering for Water based slurry handling, Spray drying,
Waste Treatment
. Hands on operation of plant equipment during 16 week strike
. Suggested, Tested, Implemented process flow method to increase spray
dryer yield by 15%
. Developed method to reclaim 40 Tons of off spec TiO2 using existing
equipment and lab specs
. RFC documents, PID & PFD development, equipment specification, process
analysis
. Investigation / Initial Dryer Upgrade Proposal to reclaim pigment & ore
. Trainer: SAP startup: BOM / Recipe / Production Schedule / COGI error /
Confirmations
Process / Project / Environmental Engineer - Platinum Catalyst Manufacture
CYTEC Industries - Criterion Catalyst, Belmont, WV July 1994 to
August 1997
. Logged, Mapped, Reported all emission points for Annual SARA and WV Air
Quality
. Removed all D009 (Mercury) Hazardous Waste from facility, per WV
guidelines
. Design / Install Windows NT Local Area Network within two Corporate HQs
specifications
. Design / Fab of Special Refillable Container, Container Loop Setup /
Management
. Design / Install Acid Scrubbers and Acid Dosing Pumps (HNO3 & HCl)
. FRP tray development to reduce $25K capital versus granite coated steel
trays
Process Engineer - Primary Metals Manufacture (Lixviation, Purification,
and Electrolysis)
Jersey Miniere Zinc Clarksville, TN December 1986 to
July 1994
. Designed, constructed, supervised system to remove mercury from
process waste streams
. Proposed, implemented fluoride purge system to re-secure zinc cathode
harvesting
. Created system to eliminate Cadmium Oxidation step, reduced exposure,
increased output 20%
. Proposed, implemented zinc dust size controls using DOE to increase
purification rates 15%
. Developed computer model of facility: predicted process flows,
concentrations, economics
. Technical junkets to sister plants, working with German, Belgian,
French Engineers.
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