Quality Engineering

JEFF M. CALAFIORE

Results-driven professional with experience spanning from project management to process trouble-shooting and quality management, who will use fundamentals of engineering as well as creativity, to achieve and exceed corporate objectives.

WORK EXPERIENCE

Environmental Express, a Cole-Parmer Company – Mt. Pleasant, SC

Quality and Continuous Improvement Manager – February 2014 – Oct 2017

Successfully transformed components of the existing quality program into a robust, functioning Quality Management System.

Prioritized quality control objectives and developed strategic plans to realize a 25% reduction in total quality complaints.

Through strategic process implementation and collaboration with department leaders, achieved reduction of quality complaints in the areas of self-manufactured products, vendor products, warehousing and shipping, and administrative functions.

Started a Quality Control Lab and developed functional tests to verify product integrity for key products.

Tests include compression force, vessel wall integrity, bubble point, and precision measurement using a Coordinate Measurement System.

Involved leadership in the quality initiatives and solidified quality performance as an individual and departmental KPI by instituting a Quarterly Quality Meeting for sales, operations management, technical team, and leadership to review quality metrics and deep dive into Pareto analysis

Formalized a non-conformance program and trained key personnel on how to conduct a root cause failure analysis and implement corrective/ preventative actions with effectiveness reviews.

Developed toll-gate process and change management process to ensure new and legacy products would meet clear functional specification and perform as industry-leading products in the market.

Building on previous experience of ISO 9001 auditing, prepared the business unit for certification through gap analysis and competitive bidding for compliance service.

Managed 3 automation projects, totaling $500k of Cap Ex, from inception to implementation.

These projects reduced labor, improved efficiencies, and limited quality-impacting variables.

Through close connectedness to manufacturing processes, identified an opportunity to standardize and optimize molding processes. Further researched molding industry standards and capitalized on an existing vendor relationship to source no-cost training for Scientific Molding, which employed the fundamentals of engineering to optimize cycle times, minimize waste, and increase over-all equipment efficiency.

DAK Americas, LLC. Moncks Corner, SC 2006-2012

Continuous Polymerization Area Process Engineer

Responsible for 24-hour engineering support for safe and efficient operation of the Staple Fibers polymerization area.

Achieved and sustained new polymer production rate of 425 metric tons per day (10% increase) by identifying and removing bottlenecks, while maximizing process equipment capability.

Reduced energy consumption by 20 BTU’s/ lb of polymer by developing a system to optimize energy consumption. Utilized thermodynamic fundamentals to maximize phase change enthalpy in the primary heat transfer fluid.

Planned and facilitated numerous polymer line shutdowns using Microsoft® Project workbooks to adhere to a strict schedule of accomplishing critical tasks and effectively utilizing resources.

Co-authored Process Hazard Analysis and Process Technology packages following PSM guidelines.

Created and implemented technology-driven training courses for chemical technicians, new process engineers, and engineering interns.

Staple Spinning Area Process Engineer

Provided 24-hour engineering support for safe and productive operations of the Staple Spinning Area

Managed recipes for 60+ products by writing and distributing work instructions and operating parameter task sheets, as well as the procedure for changing between products.

Received an internal award for waste elimination when optimizing strategy for changing recipes.

Oversaw transfer of established products from Wilmington site to Moncks Corner by adapting the spin-draw process to match product properties by utilizing process models and laboratory data.

Enhanced existing process models to balance fiber properties with spin-draw force to lower end-breaks and increase yield.

Developed a fundamental approach to reduce plant-wide spinning end breaks by 18% from historic benchmark by formulating and prioritizing action items based on research from multiple sites’ technology publications and team meetings.

Conducted behavioral-based and environment-based safety audits to identify and correct potential areas for injury.

Nitrogen Utility Optimization – Project Lead

Led project team through three levels of front end loading for capital investment of $2.2MM +/- 10%.

Evaluated multiple technologies such as nitrogen generation, vaporizer off-gas, and closed loop dilute phase convey to reduce peak nitrogen usage.

Assisted in renegotiating Nitrogen utility contract and change tier structure, in lieu of capital investment, to save 30% annual cost.

EDUCATION

University of South Carolina Columbia, SC

Bachelor of Science Chemical Engineering, May 2005

SKILLS

Strong presentation and communication skills to all levels of the organization

Strategic planning for departmental and interdepartmental objectives

Creative approach to achieve results within boundaries of available resources

Strong fundamentals in process problem solving, historian software usage, laboratory data, and communications from operations

Extensive experience Microsoft Office Suite (Word, Excel, PowerPoint, Visio, Project, Outlook).

Proficient with manufacturing operating software (Bailey DCS, Aspen IP21 and Process Explorer)

Familiar with and have practiced Lean, Six Sigma, SPC, Failure Mode and Effects Analysis, Root Cause Failure Analysis, PSM, PHA and MOC methodology

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