NICHOLAS P. ASARO

**** ******** *****

Pipersville, PA

Phone: +1-973-***-**** ac0uhw@r.postjobfree.com

SUMMARY

A 20+ Year Veteran Maintenance and Engineering Manager with extensive experience managing large automated production, process, and fulfillment environments in various industries, including Food & Beverage, Pharmacy, and Semiconductor. Very technically diverse with a focus on design, service, and maintenance of automated equipment. Consistently delivers exceptional results in the areas of reliability, accuracy, throughput, and cost of ownership reduction. Expertise in improving reliability and efficiency, leading to significant savings in production and labor costs, while maintaining high quality standards. Experience launching service centers at international locations. TPM and LEAN manager, providing leadership for teams of Engineers and Technicians. Consistently meets or exceeds delivery requirements, while ensuring fiscal savings.

PROFESSIONAL EXPERIENCE

THE COCA-COLA COMPANY, Philadelphia, PA May 2016 – April 2017

Plant Maintenance Manager / PM Pillar Leader

Plant Maintenance Manager, responsible for a 32 acre manufacturing site, with 750KSqFt of buildings, including: all Automated Processing and Production Equipment; 15KVAC Electrical Supply including 2 Sub-stations; Low and High Bar Compressed Air with 3700SCFM Capacity; Boilers/Steam Generation totaling 50,000 MMBTU/year; Ammonia Refrigeration System including 7 Reciprocating Compressors with 8 ton charge; HVAC; Fire Suppression System; Water Purification with 400kgal/day capacity. Primary responsibilities include managing $7MM annual budget, and 34 person team of Supervisors, Trades, and Operators.

In an effort to salvage a failing TPM system, deteriorating Assets, poor Quality, and low ingredient yields, developed and implemented a multi-tiered Review and Measures process, encompassing all Manufacturing and Management System. Reviews were established for Operator Shift Hand-offs, Supervisor Shift Hand-offs, and Daily Management Review. As a part of the roll-out and implementation plan training, Measures were established in collaboration with all Supervisors and Managers. After 8 months, efforts yielded a 25% improvement in Productivity, 50% reduction in Consumer complaints, and 6% improvement in yields.

During the installation and start-up of a new High Volume Bottling Line, established an Operator and Supervisor Training Program for all installed equipment, while securing $400K in funding for the successful and complete rollout of all training having taken place over a period of 7 months.

NESTLE PURINA PETCARE, CO., Allentown, PA April 2013 – May 2016

Plant Maintenance Manager / Sr. Staff Engineer II / Sr. Project Coordinator

Plant Maintenance Manager, responsible for a 113 acre manufacturing site, including: all Automated Processing and Production Equipment; 15KVAC Electrical Supply including 5 Sub-stations; Compressed Air with 3500SCFM Capacity; Boilers/Steam Generation totaling 130KLbs/hour Capacity; Ammonia Refrigeration System including 3 Ammonia Screw Compressors with 4.5 ton charge; HVAC; Rolling Equipment including Forklifts and Heavy Equipment; Waste Treatment/Containment Systems with 400KGal/Day Capacity; Fire Suppression System. Primary responsibilities include managing $12MM annual budget, and 60+ person team of Supervisors, Trades, and Operators.

As Sr. Project Coordinator for a $100MM Capital Expansion Project, responsible for the End-to-End Management of the project spanning Safety, Environmental, Quality, Production, Maintenance, Human Resources, and Warehousing, implemented a focused Project Review and Implementation Process, aimed at identifying all impacted employees and business facets, while ensuring reciprocal involvement from the Project and Factory Leadership Teams, and compliance to time-lines.

In an effort to improve Customer Service, Reliability, and Personal Development, while working within budget constraints, developed and implemented a 90-day in-house Predictive Maintenance Training Program, which produced a 25-fold increase in Level I Certified Thermography, Ultrasonic, and Machine Lubrication Technicians, contributing to a reduction in Technical Down-time of >70%.

Aimed at reducing component breakdowns and driven by a Root-cause mindset, implemented and facilitated an advanced Problem Solving Methodology Training Program, building proficiency in 20% of the Technical staff, in Root Cause Analysis, Breakdown Analysis, and Go-See-Think-Do, contributing to the total reduction in Technical Down-time.

In an effort to develop a fact-driven Issue/Action mindset, developed a set of Measures and a complimentary Review Process, encompassing the foundational elements of our Maintenance Organization, ensuring focused, data-driven activities, aimed at improving inefficiency and contributing to our overall efforts in reducing Technical Down-time.

EXPRESS SCRIPTS, INC., Bensalem, PA and Saint Louis, MO March 2004 – March 2013

Senior Manager, Engineering / Senior Controls Engineer (October 2006 – March 2013)

Managed Engineering, Service, and Maintenance of an automated, high volume, mail order, prescription-drug Fulfillment Pharmacy, equipped with 167 PLC’s, and staffed with a team of 19 Engineers and Technicians. Fiscal responsibilities include managing a $2MM annual budget.

Drove the reduction of equipment down-time from 10 impact hours per week to <5 hours per month, through the use of predictive, preventive, and corrective maintenance practices.

Designed, planned, and implemented equipment hardware and software modernizations which helped increase production volume from 65K to 85K units/day while maintaining production hours and reducing production staff by 12.5%.

Designed, planned, and implemented hardware modifications which reduced product damage, and saved $100K per year in losses.

Reduced spare parts costs by $225K per year, through the implementation of superior trouble-shooting techniques, and the implementation of an in-house repair program.

Implemented equipment and process modifications which helped reduce defects per million from 27 to 2 per month over a period of 3 years.

Secured $38K in funding for the training of service staff, which improved the overall skill-set of the team and assisted in the reduction of Equipment down-time.

Implemented a Computerized Maintenance Management Software System (CMMS), which helped track MTBF, MDT, MTTR, managed work orders, and spare parts inventory, and assisted in identifying weaknesses.

EXPRESS SCRIPTS, INC., Lincoln Park, NJ

Equipment Maintenance Specialist (March 2004 – October 2006)

Managed engineering, service, and maintenance of an automated, high volume, pharmaceutical sample fulfillment center, equipped with 16 PLC’s, and staffed with one Engineer. Fiscal responsibilities included managing a $250K annual budget.

Implemented predictive, preventive, and corrective maintenance practices which directly increased equipment availability from 95% to 99.5%.

Managed, developed, and performed equipment design and process modifications, including electrical, mechanical and software systems, resulting in the reduction of down-time.

Played a vital role in the reduction of Cost of Fill by 46%, through the implementation of new equipment processing methods.

ACCRETECH USA, INC., Oakland, NJ March 1995 – August 2003

Global Technical Support Manager / TPM QM Pillar Lead (January 2002 – August 2003)

Managed Global Field Service, Inside Service, and Final Quality Departments, which included overseeing an install base of nearly 2000 pieces of Capital Equipment, assessing Quality Control, and a staff of 15 Engineers and Technicians worldwide. Fiscal responsibilities included managing a $1.5MM annual budget.

Assisted customers with the development of predictive and preventive maintenance programs, which helped improve the customers overall ownership experience, while helping to reduce our warranty liability costs by 30%.

Created and sold service and spare parts contracts, which drove the departed to profitability for the first time in the company’s 35-year history.

Developed, performed, and oversaw, process development and process capability studies, ensuring new equipment conformed to published and customer specifications.

Developed, performed, and oversaw, MTBF, R&M, R&R, and availability studies, ensuring all new designs passed quality and performance design objectives.

ACCRETECH USA, INC., Singapore Branch Office

Asia Technical Support Manager / Equipment Engineer, South-east Asia (October 1998 – January 2002)

Resided in Singapore on an Expatriate assignment, tasked with establishing a Regional Service Center. Hired and trained new staff. Serviced all Pacific Rim and Southeast Asia Customers including an install base of approximately 500 pieces of Capital Equipment.

Worked with various government authorities to establish a branch office and Asia Regional Service Center.

Oversaw and/or performed the installation and start-up of over $10M worth of Capital Equipment, ahead of schedule and under budget, while saving the company over 10% in projected costs.

Recruited and trained 6 Engineers and Technicians.

Developed and implemented employee and customer, equipment training programs.

Assisted customers with the development of predictive and preventive maintenance programs, which improved the customers overall ownership experience, while reducing our warranty liability costs.

ACCRETECH USA, INC., Oakland, NJ

North America Technical Support Manager (May 1996 – October 1998)

Managed Field Service Department, which included overseeing an install base of approximately 1200 pieces of Capital Equipment, and a staff of 7 Engineers and Technicians. Fiscal responsibilities included managing a $600K annual budget.

Developed and implemented an on-line Failure Reporting and Corrective Actions System (FRACAS), which assisted customers and service staff in expediting repairs for commonly reported equipment problems.

Developed and implemented an on-line equipment database which managed and tracked equipment install base, service histories, and warranty status, while reducing warranty liability by 27%.

ACCRETECH USA, INC., Oakland, NJ

Engineering Technician (March 1995 – May 1996)

Responsibilities included product validation and testing, sustaining engineering, new product R & D, motion control design and programming, installing and servicing equipment, and writing technical documents.

EDUCATION

Computer Science, William Paterson University, Wayne, NJ

Digital Electronics Technology, DeVry Technical Institute, Woodbridge, NJ

MEMBERSHIPS

Advisory Member, Lehigh County Technical Institute

Advisory Member, National Institute for Metal Working Skills

Advisory Member, Lincoln Technical Institute

PROFESSIONAL TRAINING

ENTERPRISE PROGRAMS

Management Certification Program

Foundations of Management

Employee Driven Career Development

Leading High Performance Teams

Communicating and Listening

Leaders Lead

Performance Rx

Building an Environment of Trust

Developing Others

Retaining Talent

Sexual Harassment Awareness for Managers

Americans with Disabilities Act for Managers

EEO Training for Managers

TPM

Root Cause Failure Analysis

Failure Mode Effects and Criticality Analysis

Every Day Coaching

LEAN/Six Sigma

Breakdown Analysis

Leadership Trough Safety

Train The Trainer

Living in a VUCA World

ROCKWELL AUTOMATION PLC Training

ControlLogix System Fundamentals – CCP-146

ControlLogix / RSLogix 5000 Programming – CCP-151

ControlLogix Project Development – CCP-143

Motion Control Fundamentals – CCN-130

RSLogix 5000 Motion Programming – CCN-142

ADEPT TECHNOLOGIES Robotics Training: Cobra, SCARA, and Quattro Maintenance and V+ Programming

GENMARK AUTOMATION Robotics Training: GPR Maintenance Program

BROOKS AUTOMATION Robotics Training: Atmospheric Robot Maintenance Program

TECHNICAL ADDENDUM

CONTROLS / PLC

Allen Bradley

Siemens

Delta Tau

Galil

HMI / SCADA

Allen Bradley PanelView

GE Intellution iFIX

ROBOTICS

Brooks Automation

Genmark

Bosch

Adept

ABB

Fanuc

CNC

Mazak

Fadal

Milacron

RETORT SYSTEMS

FMC Foodtech Hydrostatic

ALLPAX Horizontal Spray

MALO Vertical Steam Vessel

BLOW MOLDING

Sidel, KHS

PACKAGING

Pearson Case Sealer and Case Erectors

Alvey, Wayard, Simplimatic, Whalon, ACME Palletizers

Stolle, H&K, KHS Fillers

Krones Labelers

KHS Kister, Douglas, Brenton, Hartness, Pearson, ACME Tray Packers

Angelus Seamers

Goldco, Clevertech, Simplimatic, ACME De-palletizers

Wafer Processing Equipment

Accretech Edge Profilers / Polishers

Accretech Surface Polishers

Accretech I.D. Ingot Slicers

Accretech Wafer Sorter

Accretech Wafer Probers

Applied Materials Ingot X-ray

Applied Materials Wire Saws

Applied Materials Slurry Recovery System

Applied Materials Solar Ingot Squaring Wire Saws

GAGING PRODUCTS

TSK/Zeiss CMM

OGP Avant and Smart Scope

Contact this candidate