Chemical/Rubber/Plastics Operations/Engineering Management

Brian Connolly

**** *********** *****, ******, ** 44236

Cell: 234-***-**** E-mail: **************@*****.***

EDUCATION

University of Akron – Akron, OH

Bachelor of Science, Chemical Engineering May, 1988

Focus on Polymer Chemistry and Processing

Cum Laude

University Honors Scholar

SKILL KEY WORDS

Chemical engineering

Batch and continuous processing

Process heat exchange

Organic and silicone synthesis, polymerization

Rubber compounding, mixing, extrusion

Solids and liquid handling

Capital project management

Chemical process design

PLC and DCS automation

Preventive, predictive maintenance

Operations management, union and non-union

OSHA, EPA, Process Safety Management, Title V

Inventory management

Global supply chain management

Human resources

ISO 9001, Lean/Sigma

Budgets, P/L

Product costing, economic analysis

EXPERIENCE

Shin-Etsu Silicones of America – Akron, OH 1995 – Present

Akron Site Manager 2008 – Present

Member of global manufacturing and quality team:

Developing distributed manufacturing plan for North and South America.

Developing and implementing global manufacturing and quality control systems, including corporate and US-based methodology for Lean/Six Sigma.

Developing and implementing global standards for environmental, safety and health

Completed cost estimates for a five-year $100MM capital plan, ten-year $500MM capital plan. $50MM currently approved.

Completed batch and continuous automation strategy for green-field production units using Rockwell Automation technology.

Completed North American based Elastomer Research and Development and Technical Service Center.

Manager of over 100 staff in the following functions:

Manufacturing at three separate locations. Annual manufacturing sales of $75MM.

Engineering, maintenance and plant automation departments, including all capital planning and projects.

Environmental, safety and health department, administration of employee wellness program.

Corporate customer service, purchasing, inventory and logistics departments.

Quality assurance.

Research and development department.

Pilot scale production and small volume packaging department.

Technical service department.

Developed 5-year $100MM multi-facility capital and automation strategy for manufacturing. Current project manager for the first $30MM.

Implemented Lean and Six Sigma manufacturing principles to turn around an unprofitable silicone rubber manufacturing facility in less than 2 years during the 2008-2009 economy; eliminated $500M annually in duplicate headcount, cut inventory by 50%, reduced standard product line by 80% through rationalization of similar products, improved quality control and manufacturing processes, improved first-pass quality from 55% to greater than 90%, and grew more profitable business lines, improving operating profit by 30%.

Reduced energy consumption 10% per pound of finished product through selective automation and energy efficiency projects, annual savings exceed $200M.

Developed highly profitable pilot scale production and small volume packaging technology lab including design and implementation of several unique unit operations. Increased annual sales to $3MM annually in 5 years.

Designed and installed $2.5MM R&D lab. Designed and installed $1.5M Technical Service Lab and developed a technical service function to provide assistance to customers with application technology, developing product selection guidelines, equipment modeling, and application equipment support. Currently in 2-year $1MM capital phase to overhaul existing equipment and acquire additional customer application and testing equipment.

Plant Manager, Human Resources Manager, General Manager 2002 – 2008

Added the following General Manager duties to the Plant/Human Resources Manager duties:

Managed additional staff and budgets for corporate customer service, purchasing, inventory and logistics. Distribution side of business accounts for 70% of sales.

Developed Oracle-based predictive inventory models for purchasing and inventory management

Developed computer-based inventory models for several product types based on historical sales analysis

Developed computer-based purchasing system with multiple data model capability

Developed customer service tools for product availability, order allocation and shipment management

Implemented electronic document transfer throughout logistics chain, warehouses and customers.

Plant Manager, Human Resources Manager 2001 – 2008

Added the following Human Resources duties to the Plant Manager duties:

Responsible for all employee relations; developed and managed Employee Manual, discipline procedures, job and pay classification systems, and performance evaluation system.

Responsible for all recruitment (hourly to executive level).

Managed HR function for Texas facility.

Coordinated and managed loss prevention activities including lawsuits, Civil Rights Commission Claims, EEOC Claims and unemployment.

Developed and administered procedures for employee benefits including 401(k) and health insurance programs. Kept health insurance premiums the same for 3 consecutive years.

Implemented programs from Ohio Bureau of Worker’s Compensation which resulted in preferential insurance group rates and a reduction in premiums of over $250M over 3 years.

Trained all managers and supervisors on HR/Labor Laws and company policies ensuring legal compliance.

Plant Manager 1996 – 2008

Improved productivity 100% with no increase in labor through $3MM capital expenditure. Manufacturing improvements were adopted internationally.

Increased production output 1000% from 1997 to 2008 through high product reliability and outstanding quality performance. Sales increased from $1MM to $10MM annually.

Increased hourly and professional staff for HSE, QC, purchasing, production and maintenance to approximately 20; developed and implemented annual budgeting system by group; improved purchasing system to computer-based.

Led $500M project to convert business system from AS-400 to Windows Server based Oracle Platform and integrate manufacturing component.

Eliminated manufacturing quality errors due to raw material addition and processing issues by designing and implementing $500M semi-automated batching system with barcode validation.

Certified production and quality units to QS-9000 and ISO-9001 requirements.

Production Manager 1995 – 1996

Managed 5 manufacturing and shipping staff and manufacturing budget.

Assisted in completion of the $5MM capital project to build headquarters and start manufacturing operation in Akron, Ohio. Initial annual manufacturing sales of $500M.

Adapted Japanese operating discipline for manufacturing into an American style manufacturing system.

Developed all major systems for manufacturing plant including scheduling, inventory, purchasing, safety, regulatory, maintenance and engineering.

Ferro Corporation – Cleveland, OH 1992 – 1995

Senior Process Engineer

Capital project development and management for specialty chemical manufacturing unit. Implemented $500M in capital and safety projects in 2 years and improved capacity by 20%.

Developed unique production model responsible for commercialization of new product line, including unique process equipment and capital project for full-scale manufacturing. Pilot project was $75M with projected product annual sales of $1MM.

Process and project engineering for ceramic and plastic colorant divisions, specialty chemical manufacturing. Project engineering for $5MM high pressure reactor project.

Designed corporate automation strategy using Allen Bradley technology.

Dow Chemical Corporation – Strongsville, OH/Freeport, TX 1988 – 1992

Process Engineer

Process control and automation specialist. Automation project start-up specialist, I&E troubleshooting, process control template improvements, including process savings for extruder management reducing changeover time by 50%.

Production unit supervision and engineering for chlor-alkali and polyethylene. Completed $500M in capital projects.

Process engineering, capital project development and management. Process simulation using ASPEN, Knowledge Base Development using Level 5 Object. Process design for $10MM chlor-alkali pilot plant.

Air Products and Chemicals – Allentown, PA 1985 – 1987

Co-operative Engineering student, PVA and PVOH R&D

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