Project Manager Engineer

DUANE EARL WESTFALL, PE

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

**********@***.***

Radford, VA 24141

540-***-**** (Cell)

Experience as project manager, manufacturing manager, project/process

engineer including front-end design through detailed engineering packages

and commissioning/start-up. Develop reports and manage project financial

status in SAP. Expertise in process design, technology transfer, safety:

PSM & operator training. Manage 24/7 production operation - responsible

for production scheduling, product and raw materials inventory management,

staffing, quality, and process improvement. Broad experience in chemical

manufacturing, including with custom/toll chemical manufacturer, with a

wide variety of chemistries and processes.

EXPERIENCE AND ACCOMPLISHMENTS

PROJECT MANAGEMENT

. Manage over $2 million rolling project backlog. Develop and obtain

consensus for scopes of work in collaboration with stakeholders, and

prepare work plan, estimate, schedule, and ultimately submit formal

Appropriations Request for corporate review and approval. Lead project

team through construction and startup and fulfill financial

responsibilities and reporting using SAP. Prepare and present status

reports throughout for each project.

. Maintain over $6 million annually of customer accounts through effective

communication and technology transfer of product specifications, meeting

customer requirements.

. Manage $2.25 million plant expansion - direct design phase for

architectural, mechanical, and E&I disciplines; conduct contractor

bidding process; manage construction to meet project deadline under

budget using Microsoft Project.

. Negotiate with Federal government for $2.6 million project funding for

design and implementation of modifications to continuous process for

purifying and viscosity reduction of nitrocellulose slurries; write

contract specifications and supervise/evaluate/approve work.

. Collaborate with engineering and manufacturing on new product

introductions; initiate process improvements.

. Direct corporate effort to develop Quality Management System and achieve

ISO 9001 Certification. Maintain quality system oversight and

compliance. Write procedures and train operators as part of

Certification effort.

PROCESS / PROJECT ENGINEERING

. Establish production capacity for new $100 Million Nitric Acid/Sulfuric

Acid Concentrator (NAC/SAC) by developing mathematical model to represent

interdependency of product acid requirements, the quality/quantity of

streams feeding the NAC/SAC, and projected production mix and

stoichiometry of products manufactured by client; required collaboration

with client to obtain basis information.

. Prepare RFB Package; assist in developing Engineering Functional

Specification; Coordinate in-process interdisciplinary design review and

formally prepared/issued comments to client leading to final NAC/SAC 100%

Design package; reviewed P&IDs and design submittals to

prepare/participate in formal design reviews and process safety HAZOPS;

oversee construction progress and prepare daily reports for client review

. Develop design and proposal to upgrade 18 storage tanks to include

controls and process monitoring, and new pumps for each tank for

circulation and transfer; perform hydraulic calculations and prepare

specifications to procure pumps; develop successfully executed

commissioning plan which brought new system on-line.

. Perform unit cost analysis comparing feasibility and cost to build and

operate new manufacturing facility versus purchasing key raw material.

Develop design basis to establish raw material requirements to determine

minimum plant capacity, and evaluate storage capacity, staffing,

logistics, potential future cost sensitivities, and the cost of capital.

Coordinated research effort and wrote final report

. Develop manufacturing procedures and conduct operator training

incorporating risk assessment of raw materials and finished product and

all OSHA Process Safety Management requirements

. Facilitate transition of newly developed products from lab scale to pilot

and larger production scale

. Evaluate customer supplied technical packages for custom manufacture;

prepare cost estimates based on raw material, labor, and equipment

requirements; direct plant modification, purchasing, production

scheduling, and shipment to fulfill customer purchase order; prepare

campaign-end summary reports and product costing

MANUFACTURING MANAGEMENT

. Manage manufacturing facility with annual revenues/value of $36 million

and 16 employees. Develop and manage $2 million annual budget

. Increase productivity by 30% by cutting cycle times through increased

process efficiencies, capital improvements, and providing process

guidelines to maintain process control

. Create job descriptions and checklists to train and then evaluate

operators' competencies to help determine pay increases, assist in

personnel leadership assignments, and focus future training

. Provide training and coaching to develop conceptual understanding of

processes to empower operators to tap knowledge and experience to make

procedural adjustments based on real-time data

. Save $20,000 annually in demurrage charges by implementing a model for

ordering up to $30 million of prime monomers and coordinating receipt of

railcars with shipment of product to avoid production delays and missed

product shipment via railcar

. Initiate cost improvement savings of $150,000 annually by implementing

process and equipment modifications

EMPLOYMENT HISTORY

Wood Group Mustang, Narrows, VA (March 2012 - Present) Mustang Engineering

purchased by Wood Group; Contracted project engineering services to

Celanese - Celco Plant; plant manufactures cellulose acetate tow

Project Manager Manage capital projects on rolling basis in

collaboration with client's project sponsors. Specific projects include:

$750K repair/insulation of Acetic Acid storage tank; $500K infrastructure

upgrades to research lab; $500K purchase and safe installation of process

equipment items; $100K fire protection system upgrade at solvent tank

truck unloading station; $100K pneumatic overhead lift assist system to

reduce personnel risk of handling specific equipment items

URS Corporation, Radford, VA (June 2006 - March 2012) Washington Group

International prior to URS purchase

Project Manager/Process Engineer (November 2010 - March 2012) on projects

at Pine Bluff (AR) and Anniston (AL) Chemical Demilitarization

Facilities; also at National Energy Technology Lab (Morgantown, WV)

Lead Project Engineer (June 2006 - October 2010) on site at Radford Army

Ammunition Plant contracted by Alliant Techsystems (ATK) for work on $100

Million Acid Area Modernization - Develop design basis to establish new

acid manufacturing plant performance criteria; provide engineering design

review and project construction oversight; prepare scopes of

work/estimates for modernization projects

EIT, Inc., Sterling, VA (Jan - June 2006) Custom manufacturer of

electronic circuit board assemblies offering complete electronic design,

assembly, and testing.

Project Manager Manage customer accounts ensuring quality delivery of

custom products. Plan and coordinate production.

FRENZELIT North America, Incorporated, Purcellville, VA (2003 - 2005)

Design and manufacture of expansion joints, gasketing, and technical

textiles for the power generation and other industries.

Project Manager/Sales Engineer Develop design/proposal to meet customer

inquiries; assist field service engineers on turn-key installations.

NOVEON Incorporated, Gastonia, NC (1996 - 2002) BFGoodrich Performance

Materials when hired, the site manufactures acrylic and SBR latexes,

softeners, compounds, and printing products mainly for the textile

industry.

Manufacturing Manager Manage manufacturing facility, including plant

expansion construction project. Initially hired as engineering project

manager - promoted within 6 months.

HICKSON DANCHEM Corporation, Danville, VA (1992 - 1996) Custom manufacturer

for the chemical process industry with specialization in polymer & organic

synthesis.

Senior Process Engineer Manage customers' proprietary products from

initial inquiry and technology transfer to production and pricing.

AMERICAN CYANAMID, Havre de Grace, MD (1990 - 1992) Key supplier of

adhesives to the aerospace industry; Manufacturing, R&D, sales/service, and

marketing at this site.

Process Engineer Process responsibility for manufacturing solvent-based

adhesives/composite pre-pregs.

HERCULES Incorporated, Radford, VA (1985 - 1989) GO-CO facility for

manufacturing single and double-based propellants from nitrocellulose and

nitroglycerine.

Facilities Engineer Project and process engineering responsibilities

for the nitrating and acid recovery areas.

EDUCATION

Master of Business Administration, 1990, University of Maryland, College

Park, Maryland

Bachelor of Science in Chemical Engineering, 1984, West Virginia

University, Morgantown, West Virginia

PROFESSIONAL AFFILIATIONS - registered Professional Engineer, Virginia, No.

040*-******; member, American Institute of Chemical Engineers, National

Society of Professional Engineers

Contact this candidate