Quality Control Process Improvement

Polymer Chemistry Research & Development Materials Science Laboratory Design /Management

An aggressive contributor bringing over a decade of broad ranging, hands on experience and a track record of

success in laboratory, manufacturing and process improvement arenas. The versatility to make

significant contributions across multi departmental lines and leadership of cross functional teams and

the focus to lead specialized departments to increasing metrics and performance utilizing sound

business tactics and proficient use of analytical chemistry and engineering concepts. A data driven

decision maker and risk calculator with strong fiscal management and budgetary skills. A top

performer recognized for proficient management and direction of up to 26 professional, technical and

support staff as well as managing operating budgets of well over $1 Million.

Created, executed and made significant contribution to many high impact programs, projects and business

strategies within start ups, turnarounds, and Global Fortune 500 Leaders, amassing a set of unique

skills and abilities with the confidence to implement them effectively. An adept negotiator of multi

million dollar equipment, construction, software and service contracts, with an in depth understanding

of environmental stewardship practices and “Green” chemistry initiatives from product development

through facility design. A builder and manager of critical relationships and strategic collaborations

utilizing divergent talents to achieve shared goals and business objectives.

Core Competencies

Product Development Technical Sales Support Project Management

Competitive Analysis Quality Control Process Improvement 6Σ

Analytical Equipment Quality Assurance Team building/training

Laboratory Design Market Intelligence

Polymer Compounding Public Speaking

Patent Law Regulatory Compliance

Professional Experience

Kraton Polymers Katy, Texas July 2011 Current

World leader in the manufacturing of styrenic block copolymers (SBC’s), focused on innovation through novel molecular

architecture and market applications of a broad product portfolio.

Application Engineer

An Applications Engineer developing novel solutions for customers across multiple industry segments and markets such

as viscosity modification, oil field chemicals and down hole specialty additives, synthetic cement, adhesives sealants and

coatings, bitumen modification in paving and roofing, water based polymer dispersions, oil gels and protective films. D

The development and management of toll production processes/facilities and commercialization of new customer specific

polymeric products. This role demands extreme versatility and adaptability with a broad and deep knowledge base with a

very steep learning curve. This position is a multi-departmental role with responsibilities in product development,

production/manufacturing engineering, process improvement engineering, procurement, supplier/vendor/Toller

qualification, polymer chemistry and R&D, formulation and compounding as well as being extremely well versed in the

related industrial equipment commonly utilized in all of these fields. A strong working knowledge with the analytical,

statistical and mechanical testing equipment and methods is also required in this role to effectively monitor all of the

relative metrics involved in the processes.

Encore Wire Corporation – McKinney, TX Nov.2008 – Mar. 2011

A Global Top 25 manufacturer of insulated wire and cable products serving a multitude of markets including commercial

and residential construction, healthcare facilities and retail outlets such as Lowes via direct sales and a nationwide

network of distributers, with approximately $1 Billion USD in sales annually. A publically traded, vertically integrated

and centrally located company with a 230 acre campus of over a million square feet under roof consisting of the corporate

headquarters, five manufacturing facilities, and onsite plastic and copper rod mills as well as a state of the art 13,000sqft

Research and Development Center constructed to LEED Platinum environmental criteria.

R&D Chemist & Principal Investigator-

Retained by Encore Wire Corp. to design, equip and staff a state of the art, environmentally conscious research and

development center and develop the corresponding department. To utilize this new facilities capabilities to develop new,

innovative products allowing for new market penetration, increased market share, counter act market erosion and obtain

industry leading product performance, establish compliance with Underwriters Laboratory regulations, ISO 17025 and

ISO 14001 certifications as well as securing USGBC LEED Platinum criteria certification.

Challenges –

Pushing the necessity of a well-equipped, high-end analytical laboratory to corporate executives and board members in a

culture that previously was not research oriented and a staff that was not qualified to operate or function effectively in

such a facility. Identifying, specifying and purchasing millions of dollars of laboratory equipment, determining the

staffing needs for this facility and designing the site and structure to be certified as a LEED Platinum facility, one of only

a dozen or so in the country.

Selected Results –

Authored and presented comprehensive project charter, work breakdown structure, and cost estimation to C level

executives and local economic development committee to successfully secure corporate support and over $400K in

direct outside funding for this $6 million LEED Platinum facility.

Extensively researched, specified and purchased $3 Million dollars of analytical, electrical, mechanical and

physical testing equipment for successful completion of the laboratory.

Authored Quality Management System documentation for ISO 17025, ISO 14001 and ROHS/WEEE compliance by

a US corporation, drafted 11 job descriptions for required additional qualified staff.

Through multiple meetings with OEM and extensive knowledge of manufacturing process, designed and purchased

over $500K of manufacturing equipment allowing for new product offerings and new market entrance.

Brought technical and analytical expertise to preexisting patent infringement litigations with Encores largest and

most litigious competitor in the market by utilizing analytical testing knowledge and 3rd party contract labs to prove non

infringement resulting in the court ordered re examination of the patent in question by the USPTO, a multiyear stay as

well as the successful rejection of all claims on said patent. Provided certified deposition to opposing council regarding

a second infringement case. Both alleged infringement charges were filled prior to my personal tenure at Encore Wire.

Created a detailed work flow analysis encompassing 7 production facilities, hundreds of machines and thousands of

SKU’s to assist accounting department in the implementation of an action based accounting system resulting in much

stronger data concerning P&L, JIT inventory requirements, decreased carrying costs and LIFO benefits due to a volatile

non ferrous metals commodity market (COMEX).

Created a vendor / supplier certification database to be used by purchasing and procurement departments in an ISO

9001scorecard style distributed via mass email to vendors and the accompanying vendor response database bringing

organization, compliance and accountability to a previously lax set of protocol.

Compounding and formulation work for new product development, product optimization, raw material analysis and

component level testing for quality and process improvement opportunities (PVC, Nylon, XLPE, copper and aluminum

alloys primarily)

Extensive hands on experience with Continuous copper rod casting,drawing and stranding, aluminum alloy rolling

and drawing, thermoplastic and thermoset extrusion and compounding and the analytical and physical testing of these

systems.

Contributed to multiple departmental goals, worked on many cross functional projects and spent ample amounts of

time and effort lending my broad ranging experience, technical, analytical and engineering knowledge wherever and

whenever they could be of assistance.

Plastipak Holdings Inc.–Garland, TX April 2008 – Nov. 2008

A $1.9 Billion dollar privately held injection and blow molding of specialty packaging company. The Garland, TX facility

is a state of the art, highly technical facility of more than 1 million square feet, progressive business strategies and aggressive

quality programs. A customer list including Gatorade, Kraft foods, GM, AquaFina and many more demands superior quality

and Six Sigma levels of production are required by these accounts.

Manager of Quality Control –

Tasked with managing quality control department and programs, decreasing DPMO to satisfy corporate contracts with

customers requiring constant improvement from year to year. Maintain Six Sigma or better quality metrics, maintain ISO

9001 certification and system, handle customer relations and issues, identify opportunities for improvements in process and

finished goods quality and implement procedures to realize these improvements.

Challenges –

Being available to assist staff and customers 24 hours a day via phone or travel to site. Maintaining current trending and

SPC data on over 50 production lines ranging in speeds from 8000 – 62,000 finished products per hour, a laps in control at

these speeds creates massive amounts of scrap and all of the accompanying incurred losses rapidly. Dealing with high

profile and extremely demanding customer base. Leading process improvement teams separated over 3 shifts and 7 day

production schedules.

Selected Results –

Management and manipulation of ISO 9001 quality management system, focused on “Zero Defect” resulting in true Six

Sigma levels of operations quality, less than 3.4 DPMO. Participated in Management Review process presenting trend

analysis, metric improvements and continuous improvement opportunities.

Initial responder to customer concerns or issues related to product quality, continuous improvement and new product

development. Many on site visits with customers to discuss product performance and opportunities for improvement,

maintained close contact and strong relationships with customers.

Direct management of 26 quality control inspectors and regulatory staff members over 3 shifts, seven days a week.

Responsible for all product and facility quality requirements as well as training, scheduling, evaluating and continuous

support of staff in a state of the art facility with over 1 million square feet under roof, month over month

performance gains.

Fostered and developed strong trusting relationship with high profile clientele that was previously a source of discontent

for both parties, creating a much more open, trusting and amiable working relationship.

DOE (Design of experiment) Six Sigma (Yellow Belt $100K project)

SPC (statistical process control) RCA (Root Cause Analysis)

FMEA (failure mode /effects analysis)

HACCP (hazard analysis and critical control point)

*Substantial decrease in sales volumes due to volatility and decreases in the market and customer base led to sweeping

reductions in force and given my brief tenure I was one of many to be laid off with a severance package, creating a very brief but

learning intensive tenure at Plastipak.

Consolidated Container Company – Sherman, TX June 2007 – April 2008

A 2600 employee blow molding company utilizing multiple polymer feeds and specializing in production of specialty

containers and rigid packaging solutions.

Manager of Quality Control & Process Improvement Engineer –

Management and direction of the quality control department and the implementation of strategies, protocol, concepts and

philosophies to decrease non-conforming product, limit defective product received by customer base. As a true hybrid

position, process improvement and optimization was also included in this job description.

Challenges –

Coming into a less than efficient process with a severely limited budget facing the task of creating and implementing a

dramatic change in culture. Gaining a solid working knowledge of antiquated and heavily used production equipment and

the less than consistent process controls in place.

Selected Results –

Traveled to key account locations and co developed customer specific action plans for each, returning and

implementing these multi component processes to dramatically improve customer relations and the quality of product

the received.

Set up SPC programs, trained operators, mandated 100% inspection with automated testing equipment, dedicated

quality control personnel to specific production lines resulting in extensive reductions in held ware, non conformances

and scrap rate

Capital equipment purchases and retrofit projects of $300K decreased down time, improved quality, and increased

efficiency, allowing for increased capacity and expanded product line (proved ROI in 90 days).

Henkel International – Lewisville, TX Aug. 2002 – July 2007

A $21 Billion Fortune Global 400 company with 48,000 employees that enjoys globally leading product lines in multiple

markets, specializing in adhesives, sealants, surface treatment, home and personal care products.

Development Chemist –

Support a sales force of over 100 strong in product recommendations, application assistance, new product

development and create value added solutions/products to ever evolving set of customer needs.

New Product development, multiple patents US and International.

Provide excellent technical support to sales force over 100 strong (line trials at customer, all product

recommendations, etc.)

Through extensive testing determine alternative raw materials/substitutions to combat margin erosion due to supplier

price increases while maintaining a quality product.

Field customer application data and through rigorous testing recommend or develop a product to meet their specific

requirements.

Serviced a very broad range of industries and applications from food packaging, automotive, construction to high end

niche markets such as the space shuttle.

Investigated customer claims and reconciled in excess of $250K a year on average, and $500K in 2007 alone.

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