Engineer Process

JACK CASTELLI

San Diego, CA H: 760-***-****

********@*****.*** C: 619-***-****

Results-oriented Manufacturing Manager and experienced Process Engineer

with broad-based background in new product/process development and high

volume manufacturing environments. Proficiencies include providing clear

direction with organizational goals; implementing systematic solutions that

focus on sustainable improvements with superior controls; and communicating

effectively with all levels on company strategies and direction. Team

player, change catalyst and tenacious achiever with creative problem

solving abilities, extensive experience and accomplishments in the areas of

process improvements and cost reduction utilizing Six Sigma and Lean

Manufacturing strategies.

Continuous Improvement - Six Sigma Black Belt - Manufacturing Management -

Design of Experiments

Theory of Constraints - Lean Manufacturing - Troubleshooting - Project

Management - Process Development

Data Analysis - Budget Development and Control - Cost Reduction -

Statistical Process Control

PROFESSIONAL EXPERIENCE

BOSTIK, Temecula, CA 6/2009

- Present

Global leader in the adhesive and sealants marketplace with solutions for a

variety of markets including residential construction, personal care and

hygiene, packaging and many others.

Sr. Process Engineer

Continuous improvement leader for manufacturing processes including

urethanes, grouts, thinset mortars and mastics for energy and waste

reduction; eliminating nonconforming material by root cause analysis and

corrective action identification and implementation; and safety

improvements through incident investigation facilitation and conducting job

and material hazard analyses. Contributing member of the Plant Leadership

Team and Safety Team.

. Led a project team to increase urethane production throughput by 41%

utilizing Theory of Constraints principles.

. Coordinated, planned and conducted plant trials with R&D to reduce

shipping costs by >$400k per year for powders products, to break into

new markets for urethane products, and for alternative raw material

suppliers for cost reduction.

. Developed, trained coworkers on, and implemented an improved

Management of Change system resulting in a compliance increase of

700%.

CP KELCO, San Diego, CA

1993 - 2009

Leading producer of specialty chemicals with facilities in North America,

Europe, Asia and Latin America.

Operations Manager (Manufacturing/Production: 1/2007 - 3/2009)

Managed and provided technical leadership for an ISO 9001- compliant

manufacturing plant operating within an $80M budget producing innovative

biopolymers used as suspension, viscosifying or gelling agents for food,

industrial, oilfield, personal care and pharmaceutical applications.

Direct reports included 5 Area Leads and >120 indirect reports consisting

of Process Engineers; Supervisors; Lab Technicians; clerical staff; and

union personnel including Mechanics, Material Handlers and Operators

. Lean Manufacturing: Conducted 5S/Kaizen events; designed and implemented

a Pull system for finished goods replenishment in support of an inventory

reduction initiative of 57%.

. Recognized by leadership as the International Safety Rating System -

Subject Matter Expert for Critical Task Analysis, Plant Safety Committee

Member and recertified site to CalOSHA VPP Star status.

. Championed Six Sigma Projects for a fermentor asset utilization

improvement of 8% by reducing turn-around-time between batches by 8 hours;

increasing distillation efficiency by 13%; improving inventory accuracy

from 86% to greater than 98%; multiple product quality / FPSR

improvements; a 43% reduction in fermentor contamination; and an increase

in recovery efficiency by reducing losses by over 1/3 at one stage of the

process.

Recovery Process Area Lead (Manufacturing/Production: 9/2005 - 12/2006)

Process optimization leadership and production scheduling for recovery of

fermented biopolymers with focus on yield, throughput rate, on-stream time,

cost reduction and product quality on 3 lines. Enforced cGMP and Safety

Policies. Managed 4 Production Supervisors, 2 Process Engineers, 1 Process

Specialist and 16 Operators.

. Six Sigma Champion and team member for project resulting in an 11%

reduction in solvent usage worth $2.4M annually in energy savings.

. Supported PR&D technology transfer of new products and processes to

Production through composing detailed processing instructions, providing

field coverage and data analysis for system optimization.

. Led work group to simultaneously achieve the highest first pass success

rate and throughput in history of the site.

Sr. Process Engineer (Manufacturing/Production: 5/2004 - 8/2005)

Optimization for quality and throughput of filtration, precipitation,

pressing, extrusion, drying and milling systems. Troubleshooting, new

equipment start-up and operator training. Coordination of Maintenance and

Project activities with Production schedule. Direct reports included 4

Lead Operators.

. Created Preventative Maintenance procedures for pressure leaf filtration

and dilute phase transfer systems leading to a 7% increase in on-stream

time.

. Re-engineered a pressure leaf filtration system to reduce time to achieve

clarity from typically greater than 10 minutes during each transition to

less than 2 minutes, lengthen typical filter cycles by 30 minutes and

reduce product losses.

. Trained as Six Sigma Black Belt for Operational Excellence and led a

yield increase project resulting in $1.3M annual savings utilizing C&E

Matrices, FMEA, SPC and DOE.

Process Engineer (Manufacturing/Production: 6/2001 - 4/2004)

Created, developed and implemented process improvements in precipitation,

drying, milling and blending processes, resulting in increased throughput

and quality with decreased cost. Troubleshooting, new equipment start-up

and operator training.

. Designed and implemented a heat transfer process for increasing product

viscosity by 45% to meet customer needs.

. Led debottlenecking projects resulting in a 33% increase in recovery

throughput on each of 2 lines.

. Developed a sterilization process allowing rework of otherwise unsellable

material generating greater than $2.8M in revenue.

Project Engineering and Design (Engineering and Maintenance Departments:

6/1993 - 5/2001)

Engineered, designed and drafted capital projects, from preliminary design

through construction. Hired, trained and supervised designers to perform

similar duties.

. Designed, engineered and installed a system for injecting a liquid

dialdehyde into each of 3 Ribbon Blenders facilitating a WIP reduction of

400 MT; slashing product changeover time from greater than 24 hours to

less than 8 hours; and reducing raw material consumption by 90%.

. Established and preserved compliance with OSHA Process Safety Management

requirements through field verification and development of accurate

documentation.

. Emergency Response Team member.

. Other projects include: feed train heat exchangers for a distillation

system; solvent recovery system, chlorine and isopropyl alcohol scrubbing

systems; regenerative catalytic oxidation system; and fed batch

fermentation.

BDK Engineering, San Diego, CA 1/1992 - 5/1993

Drafting

Drafted lighting and receptacle layouts; MCC elevations; and single-line,

ladder, and piping and instrumentation diagrams for architectural firms,

reclamation facilities, and hospitals. Additional responsibilities

included training new hires to use AutoCAD and coordinating small projects.

FORMAL EDUCATION

University of California, San Diego

Bachelor of Science, Chemical Engineering

. Provost's Honors each quarter, Magna Cum Laude, 3.91/4.00 GPA

. American Institute of Chemical Engineers - President of Student Chapter

. IM Softball

. Tau Beta Pi Engineering Honor Society

ITT Technical Institute, San Diego, CA

Associate of Applied Science, Computer Aided Drafting Technology

. Most Outstanding Student Award

TECHNICAL, LEADERSHIP AND MANAGEMENT TRAINING

. 5/2010: Leadercast Seminar

. 12/2009: Quality Management System - Expert

. 9/2009: Quality Management System - Specialist

. 11/2008: How to Deal with Unacceptable Employee Behavior

. 6/2008: Advanced Excel Training

. 5/2008: FranklinCovey - Leadership Greatness Summit I

. 11/2007: FranklinCovey - Seven Habits of Highly Effective People

. 6/2007: Kepner-Tregoe - Problem Solving and Decision Making

. 1/2006: Six Sigma Black Belt for Operational Excellence

. 9/2005: Managing in the New Millennium

SOFTWARE AND CONTROL SYSTEMS

SAP ERP - Minitab - JMP - Word - Excel - PowerPoint - Visio - Access -

Movex - PI Data Historian

MachSix - AutoCAD - SPC XL - LabVIEW - MATLAB - Siemens APACS DCS -

Rosemount RS3 DCS

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