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Engineering Plant

Location:
Mason, OH, 45040
Posted:
July 24, 2017

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Resume:

Gregory A. Freeman

**** ******* **. *****, **** *5040

513-***-****; ****.*********@*****.***

EDUCATION

University of Cincinnati, Bachelor of Science

Graduation Date: June 1995

MAJOR: CHEMICAL ENGINEERING

PROFILE:

I am an energetic professional with a track record of achievement in Engineering, EHS & maintenance department management. Over 20 years of Engineering experience in industries serving Polymer/ Chemical, FDA/ GMP, Bio-fuel and ISO/ QS regulated facilities.

WORK EXPERIENCES

Chemical/ Polymer plant: Role: Engineering/ Maintenance & EHS Manager December 2012 - Present

Summary: Provide oversite of Engineering, Maintenance & EHS departments for a chemical polymer adhesive PSM manufacturing site. The role includes both asset and personnel management.

Engineering Management: Responsible for the Plant Engineering Capital Project Planning and Execution to implement project/ process improvements. Projects include process & control system upgrades as well as facility building and property projects.

PSM – Process Safety Management: An experienced PSM professional. Established a solid PSM program for the polymer manufacturing plant. In an EPA Audit in 2015, the inspector deemed the program as “World Class” and was impressed with the dramatic improvement from 2009. Provided leadership to establish the plant’s Mechanical Integrity, Employee Participation & Training, and the Process Safety Information. Established a culture that accepted the MOC – Management of Change requirement.

Maintenance Management: Direct reports included the Maintenance supervisor and technical facility personnel. Oversaw the establishment of a solid CMMS based preventative/ predictive maintenance program (MP2). Instituted a spirit of “Plant Customer Service” to build a bridge between the maintenance, production and management.

Engineering Excellence: Direct responsibility for all engineering upgrades at the plant. Collaborative approach to creating and executing engineering initiatives.

Environmental Role: Provided an oversite role to ensure the MSD, EPA & Storm Water Permits were kept compliant and up to date. Provided a schedule and executed action items to eliminate any NOV non-compliances. Provided the 24 hr. point of contact for all plant emergencies and incidents.

Plant Safety: Responsible for the plant safety/ security activities for the plant and personnel. Partnered with personnel to create a culture of safety responsibility. Established the behavior based safety program “STOP”. Oversaw the management of the Incident Investigation resolution process. Respiratory protection, fall protection, LOTO, hot work & confined space.

SAP: Proficient in SAP management system. Primarily utilizing for Budget management, P.O. placement and safety initiative budget planning.

Community Collaboration: Local police, fire and emergency responder contact 24 hrs/ day. Site security officer contact for the Department of Homeland Security and DOT.

Plant Asset / technical base management: Define & approve all plant PFD’s, P&ID’s, Electrical & general plant drawings and procedures. Create or modify all plant drawings with AutoCAD. Modify & control distribution of DCS & PLC programs, elementary instrumentation drawings & records.

Controls Engineering: Provided site PLC programming and troubleshooting for GE 9030, Allen Bradley PLC-5, SLC 500, Pico & Micrologix & Horner PLC/ HMI controls.

New Energy – Biofuel (ethanol): Plant/ Project Engineering Manager December 2006 to November 2012

Summary: Provide the Plant/ Project Engineering leadership for a 24 hr. 100MM gallon fuel ethanol plant. The role encompasses a wide variety of Process/ Project Engineering Management, Plant Maintenance management, Environmental Permitting, Contractor Management & Safety Support. Provide a 24/7 commitment to operations – on call.

Plant equipment/ Process specification: Define specifications for all plant equipment & materials used (solids conveyors/ screws, pumps types, heat exchangers, hammer mills, centrifuges, civil, HVAC, instrumentation, bag-houses, silos, demin systems, distillation, DCS & PLC equipment, chemical treatment systems & environmental testing equipment). Example process materials: liquid handling, powders, coal, caustics, acids, flammables, natural gas, steam, polymers, surfactants, waste sludge & plant effluent.

Liquefaction Productivity Team Leader: Designed and installed a cavitation system complete with pumping systems, control valves, piping, flow meters, RTD’s, pressure transmitters & sealant systems. Process provided slurry particle size reduction while in liquid form (Installed into a Class II, Div. II electrical classification). Created DCS operator screens & process logic to integrate into existing production process. Managed all labor & asset investment budgets (mechanical, electrical, pipefitters & masonry contractors). Project was completed ahead of timeline & below budget.

Plant Maintenance Management: Managed Controls and Pipe Fitting maintenance department area in all disciplines (Electrical technicians, Mechanics & pipe-fitters). Managed the plant mechanical integrity program to comply with osha, EPA and the Department of Homeland security requirements. (Plant wide pressure vessels, heat exchangers, boilers & relief valves).

Capital Plan Management: Create and execute the capital project plan for corresponding engineering & maintenance projects with an emphasis on maximizing profits, safety & environmental permit compliance. DDGS Supply chain Profitability project: Design & installed a large scale hammer mill particle size reduction & conveying process to maximize profits with regard to DDGS product. Project/ process equipment installed: New DCS automation equipment & programs, Electrical motor control center, explosion suppression systems, bucket elevators, rotary screw conveyors, rotary airlocks, modulating slide gates complete with bag house fan filtration systems. Created all drawings (Electrical, DCS screens, foundations & structure, PFD & P&ID’s). Managed all disciplines of contractors: Electricians, DCS consultants, Millwrights & Masonry companies.

Plant Asset / technical base management: Define & approve all plant PFD’s, P&ID’s, Electrical & general plant drawings and procedures. Create or modify all plant drawings with AutoCAD. Modify & control distribution of DCS & PLC programs, elementary instrumentation drawings & records.

Environmental Engineering & Cost reduction: Decreased fines & releases by implementing environmental equipment installations. Responsible for environmental treatment plant equipment. Provide modifications, maintenance, procedures & training for site operators & maintenance techs. This includes the following automated processes: Effluent treatment systems, ph neutralization, DAF polymer solids control, RTO (Regenerative Thermal Oxidizer), coal desulphurization system & plant wide VOC flares.

Plant Safety Team: Partner with safety, operations & maintenance to create & manage the OSHA process safety management program, safety equipment installations, pm’s & operator procedures. This includes: plant contingency plan development, HAZOP team coordination, Near miss solution team. Trained as a plant emergency responder. Manage MOC for all site process or procedural changes.

Kimberly-Clark, Appleton, Wisconsin: Engineering Consultant/ Contractor Nov. 2005 -Nov 2006

Summary: Appleton Corporate Research center for Kimberly Clark FDA/ USDA facility.

Completed a supply chain logistics project to improve profit margins by relocating manufacturing plant production lines from Neenah Wisconsin to new manufacturing sites for sanitary manufactured products. Project financials & timelines met team goals.

USDA/ FDA clean manufacturing environments & processes. Manufacturing lines included a variety of equipment, tanks, pulp, pumps, packaging equipment & palletizers.

FPS, INC, Cincinnati, Ohio; Project/Sales Consulting Engineer April 2001 – October 2005

Initiated FPS incorporation for chemical engineering consulting services & sales.

Directed sales/ engineering projects commercial and industrial markets in greater Cincinnati/ Dayton/ Northern K.

Oversaw product line definition/ Production contract setups/ financial decisions/ Engineering.

Procter & Gamble, Cincinnati, Ohio; Engineering Consultant/ Contractor

Provided engineering & design development supporting new consumer product commercialization.

Developed project schedules & deliverables for GMP/ FDA Solids & liquids conceptual process equipment design including pilot scale engineering to solidify process options.

Led pilot process development work ultimately defined production process – defined process taking full account of physical property boundaries & product quality specs.

Defined the plant manufacturing for the startup of facility, process and raw material handling based on economic modeling.

Krauss-Maffei, Cincinnati, Ohio; Engineering Consultant – Project Manager

Automotive Reaction Injection Mold equipment Project Engineering / Sales support for the manufacture of automotive poly-urethane components. Mold carrier drawings & manufacturing; implemented contract Manufacturer modifications for reaction injection molding Equipment supporting assigned project.

Unilever - Diversey, Cincinnati, Ohio; Plant Engineer / Maint. Mgr. March 98 – April 2001

Summary: Plant Engineer, 3 shifts JIT Liquid/ Powder Industrial Chemical Manufacturing Plant. In addition to Engineering, performed Maintenance department management with 14 employees - PLC techs, welders, mechanics, purchasing & coordinators.

Liquid Production Team Leader: Partnered with production employees to provide engineered, procedural, upgrades to increase profit contribution to serve supply chain.

Manufacturing Profitability Projects – Engineered Production Lines: (Drum lines, Pail lines, Quart & Gallon Lines) Designed layouts and partnered with hourly personnel to provide installation of equipment and filling control systems to expand & improve Sharonville’s packaging efficiency relative to small packaging, flammable packaging, and bulk solids/ liquid.

Production /Profit upgrade - Sodium Hypochlorite: Automated the Manufacturing Process for supply chain. Project management from preliminary design to the installation and start-up of processes. In addition, operating/ safety procedures and provided training to the operation’s team.

Bulk Chemical silo & bulk liquid raw material cost projects – Designed and installed a variety of bulk chemical storage systems to lower manning & improve flexibility for rail & tank wagon. Designed pumping systems, control logic specific to chemical properties of the raw materials involved. New raw material methods eliminated unsafe practices as well.

Implemented Profitable Homogenization Process for Industrial Slurry Products – Process equipment and procedural logic to improve the quality and reduce cycle time of manufactured slurry products.

Additional Management Responsibilities: Site Fire prevention systems, Freight & passenger elevators, all HVAC, Plant Utility Facilities & Boilers, all chemical processes and buildings & asset budgets.

Predictive / Preventative Maintenance – Implemented Preventive & Predictive maintenance procedures & methods throughout facility using CMMS. Maximized asset life, minimized downtime, increased maintenance customer service to the 24 hr. production site (Bulk Chemical, railway system, reactors/ blenders, plant facilities, packaging, tow motors, elevators, pumping systems, etc.)

Provided Effluent and MSD control for Manufacturing/ Research & Corporate site. Continuous electronic pH and gal/ min monitoring with alarm conditions tied to my personal beeper 24hrs a day to ensure MSD compliance and Sharonville City safety.

Led Union & Non-Union Sharonville Environmental Compliance Team: Partnered with Production Union and Supervisors to eliminate gas clouds & solids chemical releases and improve profitability.

Jergens, Cincinnati, Ohio; Process Eng/ Scientist II R & D Development June 95 – March, 98

Summary: Developed and implemented production processes (including securing two engineering patents). Coordinated production startup for processes, outsourcing contract & profitability. All Biore manufacturing margins were defined and implemented to 70%+ margins. FDA/ USDA facility.

Led the production startup of Biore products manufactured at contract manufacturers (80% of Biore’s products were contract manufactured).

Co-invented and secured several Process Engineering design patent applications for Jergens. (Accepted by US Patent office).

Designed and submitted three other Patent applications for processes which produce intermediate collapsible beads (vacuum dry granulators/ particle size reduction) which enable Jergens to enter a new market segment and capture 10MM+ in sales. (Biore Self-heating mask, Biore daily cleansing scrub.)

Wrote the GMP production packet surrounding handling of raws, compounding procedure, material transfer and storage, packaging, and safety precautions.

Provided safety and operator training of research individuals for 32 varieties of pilot plant equipment (examples: spray dryers, extruders, presses, double motion vessels, etc.)

Givuadan-Roure, Cincinnati, Ohio; Intern-Project Engineer April, 93- Sept., 95

Summary: Provided project engineering role for the construction of an USDA food flavoring plant. Responsibilities primarily supported the Senior Project Engineer.

Ashland Petroleum Refinery, Ashland Kentucky; Intern-Project Engineer April 91 – April 93

Summary: Provided refinery control project engineering role. Responsibilities primarily supported the Senior Project Engineer.

REFERENCES:

Available upon request



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