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Engineer Project

St. Charles, Illinois, United States
February 19, 2018

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Alan Beyer Saint Charles, IL *****

Senior Project Engineer


Industrial engineering professional with diverse experience in R&D, design, and manufacturing. Background consists of product design, tooling design, research and development (R&D), measuring (SPC), design of experiments (DoE), Six Sigma methodology (6σ), Continuous Improvement & Total Quality Management (TQM). More than 15 years of experience supporting plant operations; specifically, high-speed manufacturing equipment used to manufacture 2PC DWI cans, and filling operations for vacuum packing. Extremely familiar with product specifications and requirements needed to maintain World Class operations. Emphasis on safety and 5S.


MAPEI Corporation, West Chicago, Illinois Nov 2015 to present Mapei is a worldwide leader in the manufacture of total systems for the installation of floor coverings in commercial and residential construction. The company’s products include mortars, grouts, adhesives and admixtures.

Senior Project Engineer

Responsible for managing global corporate engineering initiatives by means of directing, planning, coordinating, and overseeing activities to meet the company’s current and future business needs. Projects consist of; building upgrades, specifying and ordering new equipment, conducting factory acceptance testing (FAT), and working with OEM. Oversaw the installation and commissioning of a 2MM packaging line, including two Arodo bag fillers, one Mollers palletzer, and one Arodo stretch hooder. This work required writing installation specifications, developing RFQ, soliciting vendor quotations, managing timelines, and overseeing the entire project. I led multiple teams (mechanical and electrical) simultaneously, in order to meet stringent deadlines. Work was completed on time and within budget. Managed bag filling packaging for thin film (filling, vacuum packing, palletizing and stretch hooding) Led project scope, budget, process planning, permitting, execution, and control of assigned CapEx projects

Managed contractors and OEMs for purposes of building, equipment installation, and process buyoff

Led engineers and technicians for purposes of completing capital projects. Executed continuous improvements and increased efficiencies in operations by 40% (48.3% vs 80%). Focused on best practices, 5S initiatives, and standard operating procedures. Developed budgetary constraints and RoI analysis for CapEx projects, while achieving best in class outcomes. Transformed working environment into a collaborative effort, while at the same time increasing moral

Crown Packaging Technologies, Alsip, Illinois 2000 to 2012

Crown is a U.S. based company that operates in 40 countries, employs 23,000 people and has net sales of $9.1 billion. The company brings best practices in quality and manufacturing to the U.S. and growing economies in Asia, Eastern Europe, South America, Middle East and North Africa.

Project Engineer

Managed multi-million dollar R&D projects with emphasis on continuous improvement, cost reduction, increased efficiency, standardization, new product development, quality control, line speed-up and reduced tooling usage. Provided engineering innovation and direction for the introduction of products and processes from startup through implementation. Designed, installed and commissioned customized equipment. Proactively identified and eliminated sources of variation to improve product quality, consistency, and yield. Developed and delivered training programs for manufacturing operations.

Generated training materials for front-end DWI can forming process and delivered training to core business personnel. This work consisted of working with suppliers, referring to OEM documentation, and interviewing subject matter experts (SMEs). Documentation and training enabled consistent execution of manufacturing processes. RoI payback less than six months. Managed the commercialization and technology transfer of new processes into five newly built plants in Asia. Designed and specified tooling, ordered & organized deliveries, and identified engineering specifications for manufacturing. Delivered training to AP region, requiring International travel to China, Cambodia, Vietnam, Thailand, and Singapore. Improved process efficiencies by 4 times. Recognized as an expert in die necking technologies and was asked to generate training materials to educate core business personnel. Delivered training to all U.S. beverage plants. This project was prioritized as a number one priority, and sponsored by the president of U.S. operations. Optimized European operations by means of standardization and process improvement. Designed and trialed new processes, and verified data using statistical analysis. Traveled to UK, Greece, & Turkey for implementation & standardization. Supported the introduction of Coca-Cola Full Throttle product launch by designing tooling, testing and evaluating pilot production, and delivering manufacturing standards. This piece of work was delivered on time, within budget and met the customer’s high expectations for quality. Delivered tooling design improvements which improved efficiencies, and captured annualized savings 4MM. Led a corrective action team (CAT), which delivered standardization across U.S. beverage division; recaptured annual waste of more than 2.5MM. Proactively identified and eliminated sources of variation, improved product quality & consistency, and reduced spoilage by 50%. Developed gauging technology which increased the life expectancy of worn tooling. Eliminated effects of tolerance stack-up and out-of-roundness conditions. Recaptured hundreds of thousands of dollars in rework. Used Six Sigma techniques to measure and quantify the effects of engineering changes (e.g. DoE, ANOVA, scatter diagrams, linear regression). Made recommendations based on modeled confidence intervals.

Alcan Aluminum Corporation, Aurora, Illinois 1995 to 1999

Alcan started in 1902 as Northern Aluminum Company, the Canadian subsidiary of the Pittsburgh Reduction Company (later Alcoa). It was renamed Aluminum Company of Canada (Alcan) in 1925 and separated from Alcoa in 1928

Design Engineer

Product and tooling design for the aluminum D&I packaging industry; including can-forming & die necking technologies, end-forming & conversion processes, and riveting forming technologies. Interpretations of customer tooling assemblies and collaboration with customer senior management. Made recommendations for improvement, and cost reduction strategies. Completed competitive analysis of industry standards. Published industry wide double seaming paper on Microseam technology Presented findings of Microseam performance characteristics to Anheuser-Busch Corporation. Optimized can forming operations in support of MCC manufacturing (Anheuser-Busch & PepsiCo). Conducted feasibility studies with Kramer Group & Formatec (shell & end design). Optimized sequential necking operations for American National Can. Assisted Ball Corporation with standardization of cup forming technologies. Assisted can industry in the introduction of advanced ceramic technologies. Managed databases for tooling inventories, coil stock, engineering drawings, and file storage. Analyzed metallurgic forming properties with respect to performance characteristics Education

Master Industrial Technology & Operations Management May 2015 Illinois Institute of Technology, Chicago, Illinois, GPA: 3.8

Bachelor Industrial Technology & Management

Illinois Institute of Technology, Chicago, Illinois, GPA: 3.7 Minor: Manufacturing Technology


Green Belt Certification, 6-Sigma Specialists

Advanced Project Management, Illinois Tech

STOP Training, Dupont Corporation

Die Design for Can Making, SMEs

Geometric Tolerance, Mitutoyo Corporation

Solidworks, Fisher Unitech

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