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Manager Chemical Engineering

Location:
Easton, Pennsylvania, United States
Posted:
July 18, 2017

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Resume:

GLENN R. BURCHETT

**** ******** ***** **** 610-***-****

Bethlehem, PA 18017 ac1dae@r.postjobfree.com Cell 610-***-****

SENIOR MANUFACTURING/TECHNICAL/HSE MANAGER

CHEMICAL, PHARMACEUTICAL, POLYMERS, AND RELATED INDUSTRIES

A proven manufacturing professional and change agent with strong leadership/people skills. By being data driven, using communicated KPI’s, and a balanced scorecard; goals in the areas of HSE, OEE, OTIF, First Time Correct, EBITA, Customer Satisfaction, and Employee Satisfaction were either met or exceeded. Typical improvements using Operations Excellence tools such as: 6 Sigma, TQM, TPM, Lean, and 5S+1; resulted in financial improvements exceeding $1MM/yr. and step change improvements in all metrics. Leadership style is a “hands on” approach with extensive experience in directly managing production, HSE, HR, ERP/MRP, purchasing, maintenance, shipping/distribution, and engineering.

SPECIFIC SKILLS

PSM/RMP Implementation

MRP/ERP Implementation

Polymer Reactions

ISO Implementation/Auditor

Lean/5S

Six Sigma Champion/Green Belt

HSE/Behavioral Based Safety

Team Building

Human Resources

Batch Chemical Processing

TQM Facilitator

Capital Management

Pigments Synthesis/Processing

Numerous Cost Reductions $1M +

cGMP/FDA

BUSINESS EXPERIENCE

Honeywell, Morris Plaines NJ 2015 to Present

Performance Materials Technology

Business Implementation Leader – PSM

Led cross functional team, which brought to zero occurrences costly and serious PSM incidents.

Used Lean Six Sigma methodologies to improve compliance issues.

Led several high level incident investigations.

Optima Chemical, Douglas GA 2015 -2015

Toll Chemical Contractor

Maintenance/Engineering Manager

Assisted in the start-up of a catalyst manufacturing facility.

Assisted in the design and construction of a specialty chemicals facility.

Ametek, Winchester Plastics, Nesquehoning PA 2014 -2015

Engineering Plastics Compounding

Facilities/Maintenance/Engineering/ and EHS Manager

Implemented a cost effective plan to mitigate issues from an NOV.

Conducting Gap analysis to improve safety and productivity through targeted capital improvements.

Implementing CMMS along with PM and Predictive Maintenance.

MEL Chemicals, Flemington NJ 2013 to 2013

Zirconium Chemicals

Manufacturing Manager

De-Bottlenecked key process area improving production 20%.

Initiated Operations Excellence Initiatives: Visual factory, KPI Boards, OEE, training.

Implemented Microsoft Dynamics AX ERP.

Benjamin Moore Paints, Newark NJ 2012-2013

Commercial and Industrial Paint

Acrylic Resins and Colorants Manager

Implemented a Project to double the capacity of the colorant dispersion line.

Updated the PSM program in the Resins area with an emphasis on Mechanical Integrity and training.

Developed and implemented a capital plan to ensure robust manufacturing in the Resins plant.

Rolled out 5 S and Lean Manufacturing.

Led effort to recover plant after Hurricane Sandy.

Spartech Corporation, Donora PA 2011-2012

Engineered Plastics Compounding

Plant Manager

Managed the following Direct Reports: 2 Production Managers, Engineering Manager, EHS Manager, Shipping Manager, Human Resources assistant, Quality Manager, and Reliability Engineer.

Took a plant that was operating at a loss to a sustained +$1MM/month Gross Profit.

Negotiated a first Union Contract with the Teamsters.

Significantly improved site morale through leadership and communication.

Improved safety performance of more than 1000 lost work days prior to my tenure to a less than 8 days.

Piramal Healthcare, Bethlehem, PA 2009 - 2011

Global generic pharmaceutical manufacturer producing anesthetic gases at this site.

Manufacturing/Technical Manager

Delivered a 300% increase in production of the main production line while improving quality and safety.

Designed and implemented an “Engineering Blueprint” to meet aggressive short term goals and contributed to the “master plan” to sustain gains and position future growth.

Rolled out new product line while successfully passed FDA and EU audits.

Reduced Waste Costs by $750,000/yr.

COVIDIEN, Phillipsburg, NJ 2007-2009

Chemical Manufacturing firm producing for the high purity, pharmaceutical, and electrochemical markets.

Manager, Site Engineering

Accountable for a $12MM + annual capital budget and a $15 MM fixed cost budget.

Directed site maintenance, waste treatment, utilities, and project engineering as well as serving on the site’s leadership council.

Reduced the costs of compliance to the NESHAP standard by $10MM while reducing operating costs by $1MM/yr.

ELEMENTIS 2001-2007

Chemical manufacturing firm and market leader in the businesses of Specialties, Pigments and Chromium.

Director of Operations, Pigments Division, Easton, PA (8/03 – 6/07)

Global Operations Manager, Global Colorants/Additives Division, Multiple Locations (5/01 – 8/03)

Managed the following Direct Reports: Operations Manager, Engineering Manager, EHS Manager, Shipping Manager, Human Resources Manager, Purchasing Manager, and Quality Manager

Implemented cost savings initiatives, which repeated year on year and totaled more than $2 million/year. Savings were achieved using Six Sigma, Stable Operations, and Lean Manufacturing.

Cut OSHA recordable injuries by 75%.

Achieved ISO 2000 registration.

Through and in the aftermath of a devastating flood, which wiped out most of the finished goods inventory, managed facility to successfully meet customer needs, as well as reasonable key metrics.

Using Operations Excellence tools reduced the operating costs of the facility making North America delivered price of product comparable or lower than that of Chinese facility.

Had Site P & L accountability.

Successfully negotiated labor contract, achieving major concessions on the part of the union.

Implemented cost reduction exceeding $1 million/year using TQM tools and employee engagement.

Mitigated the impact of environmental issues, which occurred prior to tenure.

Implemented Small Media Mill Technology.

Reduced OSHA recordable injuries to zero, from 20 + per year.

PQ PQ CORPORATION, Industrial Chemicals Division, Baltimore MD 2000-2001

Plant Manager, Baltimore, MD

Significantly improved employee satisfaction, which contributed to a successful contract negotiation with no grievances in 6 months.

Doubled production through debottlenecking.

Was able to build credibly with government agencies following consent decrees prior to my tenure.

PMC SPECIALTY CHEMICALS, FORDS 1997-2000

Plant Manager (General Manager), Fords Specialties, Fords, NJ

Managed all aspects of a facility producing specialty antioxidants and Phenolic resins for the Food, Pharmaceutical, Rubber, Plastics, and Printing Industries.

Managed the following Direct Reports: 2 Production Managers, Engineering Manager, EHS Manager, Shipping Manager, Human Resources Manager, Quality/R&D Manager, Plant Controller and Purchasing Manager.

Initiated programs to achieve ISO registration.

Turned a 4-million pound/year waste stream into a $6 million/year saleable product.

Initiated programs to achieve compliance for OSHA PSM and EPA RMP.

Improved productivity by 15%.

Reduced grievances by 50%.

Significantly reduced OSHA recordable injuries.

ASHLAND CHEMICAL COMPANY, CALUMET CITY, IL 1995 - 1997

Plant Manager, Special Polymers and Adhesives Div., Calumet City, IL

Managed all aspects of facility, producing Acrylic and Phenolic resins for the Automotive, Labeling, and Medical Markets.

Achieved ISO 9002 registration.

Implemented cost and waste reduction programs saving $600,000 annually.

Designed and implemented a gain-sharing program.

Achieved highest customer quality awards from major customers.

Improved Union/Management relations through use of joint Labor/Management and self-directed teams.

OCCIDENTAL CHEMICAL CORPORATION, KENTON OH 1990 - 1995

Production/Technical Manager, Durez Division, Kenton, OH

Managed three production units, manufacturing Phenolic resins and molding compounds, along with the site Quality, Maintenance, Purchasing, and Engineering Departments.

Improved performance income more than $2 million/year through cost reductions, cycle time improvements, process automation, and TQM implementation.

Responsible for $3-5 million/year capital budget.

BASF CHEMICALS CORPORATION 1984 - 1990

Operations Superintendent, Polymers Division, Wyandotte, MI (2/89 – 11/90)

Plant Superintendent, Chemicals Division, Livonia, MI (5/86 – 2/89)

Utilities Superintendent, Chemicals Division, Huntington, WV (1/84 – 5/86)

Started up, transferred technology from Germany, and managed all manufacturing aspects of a nylon, acetyl, and polyester compounding facility.

Manufacturing contact for plant construction of the new compounding plant. Key member of team bringing project in on time and under budget.

Successfully implemented "Participative Management"

In charge of all aspects of production, engineering, and maintenance for a Urethane specialties operation.

Successfully merged two manufacturing sites.

Implemented SPC/TQM program at operator level.

Instrumental in achieving top automotive quality ratings.

Managed the steam, refrigeration, and waste treatment facilities of a $48 million/year pigments plant.

Reduced total costs $360,000 despite rising energy prices.

Established programs to insure safety improvements and environmental compliance.

EDUCATION

West Virginia College of Graduate Studies, Institute, West Virginia

Major: Chemical Engineering, Minor: Engineering Management

BS in Chemical Engineering, Ohio University, Athens, Ohio

Minor: Business Administration

Graduate Work – Two years of completed programs in Chemical Engineering

ADDITIONAL EDUCATION

Green Belt Certified

Certified in Apollo Root Cause Analysis

Phil Crosby Quality College along with four other TQM facilitation courses

6 Sigma Champion

Lean Manufacturing

Multiple HSE courses – TIR2, RCRA, DOT, First Aid/CPR, Stack monitoring, Incident Command, etc.

TQM Train the Trainer

Ammerman and Cronkite Media training

PHA Trainer/Facilitator - Arthur B. Little

Various “In House” Leadership Seminars

Energy Conservation (Boiler),

Production Optimization

Safety – Project Design

Working knowledge of Russian and German

Hold a Maryland First Class Stationary Engineers License

SKILLS & AWARDS

Various Corporate and Governmental awards for HSE improvements

Various Corporate awards for Productivity and Cost Improvements

Computer skills include proficiency with most business and technical software packages,

Networks, PLC's, DCS's, and SCADA systems.

COMMUNITY INVOLVEMENT

Active in the AICHE and the SPE

Board Member of Easton YMCA as well as Chair of the Human Resources and Safety Committees.

(200 + Person Organization)

Serve on Easton Area Partnership (Emergency Response Organization)

Served on (and helped found) Woodbridge CAP and Baltimore CAP/LEPC

Appointed to a Board Position on the Maryland Chemical Industry Council

Served as Board VP for the Hardin County Drug and Alcohol Abuse Center

Served on the Board for the Calumet City Chamber of Commerce



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