Stephen A. Winstead Jr., CSSYB *** Longleaf Pines Dr. Phone: (910)
Raeford, NC 28376 Email:
acb735@r.postjobfree.com
EDUCATION AND CERTIFICATIONS:
. University of Massachusetts (Lowell, MA) - B.S., Biological Science
. Six Sigma (Yellow Belt) - University of NC / Pfizer
SKILLS:
Leadership / Management:
0. Managing production and aseptic filling within a USDA regulated vaccine
production facility. (Pfizer / Zoetis, Inovocox)
0. Shift supervision within a FDA regulated vaccine production environment
(Pfizer, Prevnar).
0. 8 years experience managing a staff of up to 7 direct and 40 indirect
reports in both small and large companies.
0. 8 years experience in quality department, production, and laboratory
management (Chemistry, microbiology, & phage).
0. Six-sigma, TQM, and DMAIC problem solving utilization and
implementation in daily work activities and investigations.
0. Computer programs including: DELTA-V, SAP, M.S. Office (Access, Excel,
Word, Outlook), MS Project, Windows (7, Vista, XP, 2000), RAPID, LIMS
(ELEMENT, Q-LIMS, and LIMDA).
0. Authoring, issuing and approving Certificates of Analysis and product
release approvals. (3 years)
0. Creating MS Access databases and Excel spreadsheets for needed
calculations and predictive modeling. (12 years)
0. Writing and revising SOP's, investigations, CAPAs, change controls,
validation reports, and supervisory reports.(9 years)
0. Leading contamination investigations to successful conclusions in
aseptic processes and operations. (8 years exp.)
0. Hands-on auditing experience (HACCP, cGMP, aseptic design, and vendor
qualification) (6 years exp.)
Regulatory:
0. In-depth knowledge of and experience with cGMP compliant FDA and USDA
regulated manufacturing facilities.
0. Knowledge of and experience with BioTSCA, NIH, and EPA guidelines for
large-scale production of genetically modified BSL-1 and BSL-2
microorganisms. (6 years)
0. Performing federally required annual biosafety training in a BioTSCA
environment. (4 years)
Fermentation Plant Startup Experience:
0. Qualification, evaluation, and performance of CIP and SIP protocols for
stationary and portable vessels from 10L to 500k gallon reactors,
including spray ball coverage studies utilizing riboflavin. (8 years)
0. Designing, equipping, validating, and managing QC, phage, and
microbiology laboratories. (6 years).
0. 4 green-field fermentation plant startups successfully completed in 6
years (2 aerobic, 2 anaerobic).
0. Authoring all SOP's to operate and validate efficient microbiology,
phage, and QC chemistry labs (6 years)
0. Expertise in bacterial and yeast fermentation (6 years), and industrial
microbiology up to 500k gallons (8 years)
Quality & Laboratory Competencies:
0. Filter integrity testing and program qualification (WIT, diffusion,
retention testing (ASTM F838))
0. HPLC, GC, Karl Fisher, XRF, wet chemistry, and hydrometry (5 years
exp.)
0. Statistical Process Control (SPC) and Six Sigma familiarization with
incorporation into existing manufacturing environments along with
startup laboratories (7 years exp.)
0. 10 years of industrial and pharmaceutical QA/QC microbiology
experience.
0. Extensive knowledge of fermentation, aseptic design and processing,
aseptic filling, and filtration technologies. (9 years)
0. Writing and performing equipment, process, and sterility validation
protocols. (8 years exp.)
0. Analyzing and trending process and statistical data; developing SPC
charts. (6 years exp.)
0. Certified in Dupont "STOP" training and "Behavioral Observation"
training. (4 years)
0. Developing and performing sterility and limit programs for water (WFI,
USP, DI, city, and process, per USP 61 & 62), raw material feeds, and
compressed air. (8 years exp.)
Environmental Monitoring:
0. Total and viable particulate monitoring of clean rooms (class 100, 1k,
10k, and 100k), class 100 hoods, biological safety cabinets, and
compressed air systems. (8 years)
0. Environmental monitoring using RCS sampler, Met-One particle counters,
rodac plates, settling plates, slit-to-agar machines and air-
impingement devices. (7 years)
0. Development of monitoring programs for glass fibers, viable/non-viable
particles, bactero-phage, GMO, and mold (4 years)
EMPLOYEMENT HISTORY;
10/2011 - Present: (10/11 - 12/12) Pfizer (Sanford, NC): Quality
Engineer and Production Supervisor
(02/12 - Present) Pfizer Animal Health / Zoetis (Maxton,
NC): Production Supervisor
I was hired by Pfizer in October, 2011 as a quality engineer to assist with
the optimization of the manufacturing process for their Prevnar vaccine
line in anticipation of the technology transfer to their production
facility in Grange Castle, Ireland at the end of FY2012.
As a quality engineer I accomplished the following:
. Championing safety in all forms and working with site leaders and EH&S
to promote and improves site safety. This culminated in being selected
to represent Pfizer at the Carolina Star safety conference in
Greensboro, NC.
. Identifying and Optimizing inefficiencies in aseptic design, processing
procedures, and variations in SOP execution.
. Worked with diverse groups to identify and update key processing steps
with SPC charts and other tools to decrease variation, decrease cycle
time, and decrease potential regulatory compliance and licensing
exposures while increasing the accuracy of batch record execution.
. Worked with corporate quality to update quality agreements with key
suppliers and contract laboratories.
. Organizing and running both Kiazen events with diverse teams to solve
challenges and optimize the manufacturing process.
. Evaluated, identified and corrected deficiencies within the SIP system
for certain stationary and portable vessels used in aseptic vaccine
manufacturing.
In October, 2012 I was promoted to production supervisor for Shift-B of the
Prevnar manufacturing facility where I supervised 8 direct reports until
January, 2013 when production of the Prevnar vaccine was transferred to
Ireland.
Following the outsourcing of Prevnar manufacturing to Ireland I was
transferred to the Pfizer's Animal Health Division where I was promoted to
the position of team leader overseeing the production of the Inovocox
vaccine line in Pfizer's Maxton, NC vaccine plant.
As the production team lead overseeing Inovocox vaccine production I have
accomplished the following:
. Championing safety initiatives and ensuring that the production team
members were appropriately provisioned with all necessary PPE.
. Investigating and remediating a recurrent mold contamination that had
plagued the manufacturing facility for the prior 3 years.
. Investigating, remediating, and optimizing Tangential Flow Filtration
(TFF) skid cleaning procedures that were limiting throughput and
contributing to yield loss.
. Introducing real-time DMAIC and six-sigma problem solving to the shop
floor.
. Authoring and performing qualification protocols for the implementation
of a Westfalia centrifuge, Palltronic Flowstar XC filter integrity
tester, and the elimination of redundant manufacturing procedures to
increase throughput, improve sterility, decrease scrap, decrease
operational costs, and maximize opportunities to recapture production
efficiencies.
. Assisting other departments by providing statistical data analysis to
assist them in their investigations.
. Working with Procurement to establish a raw material and vendor
qualification program.
. Drafting qualification and implementation protocols featuring six-sigma
centered statistical analysis and risk analysis for utilities and
process water modifications, the upgrading of aseptic filling suite
equipment, and modifications to processing equipment and tanks.
. Championing a transition to increasingly stringent documentation, data
collection, process change control adherence, and aseptic practices.
. Revising and editing production batch records, SOP's, media outlines,
policies, and other documents relative to the daily production
operations in the manufacture of Inovocox vaccine.
. Worked with engineering to evaluate, modify, and qualify CIP recipe
modifications for all portable and stationary vessels used in
manufacturing.
08/ 2005 - 05/2011: New Fermentation Plant Quality Department Creation,
Startup, and Management.
I completed four green-field startups of fermentation plants in six years.
At each plant I was retained early into the construction phase to create,
equip, validate, staff and manage the laboratories; write all quality and
environmental monitoring procedures; hire, train, and manage the laboratory
technicians, and serving as the quality department manger (plants 2 and 4),
and laboratory supervisor (plants 1 - 4). After the plants were completed
I was responsible for quality department and fermentation optimization
(plants 1,2, and 4).
Please see "ADDENDUM 1" for additional details about and accomplishments at
each startup.
1) 08/2005 - 12/2007: Dupont, Tate & Lyle Bioproducts (Loudon, TN) -
Manger of the Microbiology and Phage Laboratories, Plant
Microbiologist, and Assistant biosafety officer. (Plant idled 09/07)
a. Aerobic fermentation utilizing a GMO E. coli K12 to ferment 1,3-
Propanediol.
2) 01/2008 - 07/2008: Greater Ohio Ethanol (Lima, OH) - Quality Manager
(Plant Closed 07/08)
a. 54MM Gal/yr Dry-Grind ethanol facility consisting of six 500k
gallon anaerobic fermentors, and two 25,000 gallon aerobic
fermentors utilizing Saccharomyces cerevisiae.
3) 07/2008 - 11/2009: ADM Polymer (Clinton, IA) - Microbiology Lab
Manager (Contract through startup phase only to 11/09. Plant idled)
a. Aerobic fermentation facility utilizing a GMO E. coli K12 to
ferment Mirel biodegradable plastic.
4) 11/2009 - 05/2011: Clean Burn Fuels (Raeford, NC) - Quality Manager
(Plant Closed 03/11)
a. 60MM Gal/yr Dry-Grind ethanol facility consisting of six 550k
gallon anaerobic fermentors, and two 50,000 gallon aerobic
fermentors utilizing Saccharomyces cerevisiae.
4/2003 - 5/2005: Millipore, Inc. (Jaffrey, NH): - Quality Control
Microbiologist II
. Filter Quality and Integrity Testing (hydrophobic and hydrophilic)
. Bacterial retention testing of finished filter units utilizing B.
diminuta per ASTM F838.
. Sterility and limit testing of process, WFI, and RO water per USP 61 & 62
. Microbiological lab support duties including: media preparation,
equipment validation, etc.
. Environmental monitoring of total and viable particles, glass fibers and
compressed air in class 1,000 clean rooms.
. Writing and revising SOP's, initiating out-of-spec reports, and writing
and performing V&Q protocols on equipment and processes as needed.
. Designing and validated a cooling system for the retention test apparatus
to enable the creation of a second shift in the laboratory.
5/2001 - 9/2002: Biotech contract worker in the Greater-Boston Area:
. 2/2002 -9/2002: Bristol Myers Squibb, Inc. (Billerica, MA) - Quality
Control Microbiologist (6 month contract)
. 11/2001 -2/2002: Macrochem, Inc. (Lexington, MA): Trans-Dermal Laboratory
Technician (3 month contract)
. 5/2001 - 11/2001: Charles River Laboratories (Wilmington, MA): Transgenic
Technician (6 month contract)
ADDENDUM 1
ADDITIONAL DETAILS ABOUT EACH FERMENTATION PLANT STARTUP
11/09 - 05/11 Clean Burn Fuels, LLC (Startup #4 - Out of Business)
(Raeford, NC)
Quality Manager (Startup #4)
Clean Burn Fuels (CBF) was the first corn-to-ethanol plant in North
Carolina. When I arrived at CBF the plant was 60% mechanically complete
but lacked a quality department, QC lab, lab equipment, and all
associated procedures and standards. CBF is the fourth green-field
fermentation startup I have worked with.
My accomplishments at Clean Burn Fuels, LLC include:
EQUIPMENT / LAB/QUALITY:
. Specified and purchased all lab equipment, instrumentation, and
consumables.
. Set up and validated all lab equipment, including HPLC, GC, Karl
Fischer, Moisture Analyzers, IC chromatograph (Metrohm 880 IC Plus),
titration burettes, centrifuge, microscope, etc.
. Wrote all quality department SOP's (approximately 60 in total).
. Designed and drafted all quality department forms, data sheets, and
databases.
. Designed and wrote MS Access (Ver. 2007) databases to collect all
fermentation, quality, calibration, equipment, SOP, MSDS, and
production data.
. Issue and approve all certificates of analysis for ethanol, wet cake,
DDGs, and syrup. Wrote and designed the COA procedure and system for
CBF.
. Maintain consumable inventories and order materials, as needed, to
ensure seamless operation of the laboratory.
. Specified, purchased, and set up the grain receiving/testing lab
equipment.
. Oversee the performance of all quality-related and mycotoxin testing
for incoming grain and outgoing animal feed products.
LEADERSHIP / MANAGEMENT:
. Wrote and managed the quality department budget to ensure budgetary
compliance.
. Trained and supervise 40 production operators in their use of quality
department equipment and procedures.
. Prepare, analyze and disseminate daily, weekly, monthly, and quarterly
quality department data reports for use by other members of management
and the board of directors.
. Created Statistical Process Control (SPC) charts and calculators
(excel based) for all calculations required to operate the plant, then
trained 40 operators in their use.
REGULATORY / ENVIRONMENTAL:
. Wrote the company chemical hygiene plan to comply with 29 CFR 1910.
. Ensured compliance with all applicable regulations including ASTM
D5501, BATFE, EPA and NC-DENR regulations.
. Authored the company's spill/release testing and mitigation programs
to ensure appropriate compliance and documentation with all EPA,
state, and local regulations.
. Oversee the monitoring and mitigation of all uncontained releases, and
ensure that all necessary testing and documentation are performed.
. Monitor the on-site retention pond on an ongoing basis to ensure
compliance with all EPA and NC-DENR regulations.
7/08 - 11/09 ADM Polymer, Co. (Startup #3 -
Contract) (Clinton, IA)
Microbiology Laboratory Supervisor (Startup Phase)
I was retained by ADM Polymer to build and manage the microbiology lab
through the startup phase. ADM Polymer is a fermentation plant that
utilizes a genetically modified E. coli to ferment Mirel biodegradable
plastic. The microbiology department was built to ensure compliance with
all applicable regulations under 21 CFR 110/111, and USP guidelines.
My accomplishments at ADM Polymer include:
1. Training and managing a staff of 4-6 full-time microbiology laboratory
technicians through the startup.
2. Authoring all microbiology SOP's to operate and validate the
microbiology and fermentation laboratory.
3. Contamination isolation, identification, mitigation and recurrence
prevention in five 15,000-gallon and ten 100,000-gallon fermentation
vessels.
4. Analyzing fermentation data for trends and fermentation health, as
well as developing SPC charts and control sheets.
5. Authoring the bioburden/sterility monitoring procedures and programs
for the following systems: DI water, phage, soil, clean rooms,
dextrose feed stock, cooling tower water, environmental monitoring,
compressed air, and all sterile ingredient addition systems.
6. Authoring validation protocols for all steam sterilizers, clean rooms
(class 1k, 10k, and 100k), bioreactors, biological safety cabinets,
and class 100 laminar flow hoods.
7. Specifying and acquiring all laboratory equipment, consumables,
furniture, and supplies necessary to fully equip the microbiology lab
and clean rooms.
8. Authoring and overseeing preventative maintenance programs for the lab
equipment, steam autoclaves, clean rooms, and hoods.
9. Authoring the Chemical Hygiene Plan for ADM Polymer pursuant to 29 CFR
1910.1450.
1/2/08 - 7/25/08 Greater Ohio Ethanol, LLC (Startup #2 - Out of Business)
(Lima, OH)
Quality Manager and Continuous Improvement Manager
Greater Ohio Ethanol (GOE) was a startup 54 MM gallon/yr dry-mill ethanol
plant where I was employed to create and manage the quality department
and quality control lab, including all associated SOP's, procedures,
policies, budgets, and structure within the corporation. As quality
manager I oversaw all matters pertaining to or having the ability to
affect the quality of final products. Unfortunately, GOE went out of
business due to a financial downturn within the ethanol industry.
My accomplishments at Greater Ohio Ethanol include:
1. Specifying, purchasing, setting up and validating all chemistry
laboratory equipment.
2. Writing all quality department SOP's and environmental monitoring
protocols.
3. Managing, hiring, training, and scheduling a staff of 3 laboratory
technicians on a day-to-day basis.
4. Ensured compliance with all applicable regulations including ASTM
D5501, BATFE, EPA and OH-DNR regulations.
5. Investigating, identifying, and correcting all process contaminations
in the plant.
6. Managing and overseeing all fermentations and matters of aseptic
technique or sampling within the plant.
7. Establishing and maintaining an annual budget for the quality
department.
8/2005 - 12/2007 Dupont, Tate & Lyle Bioproducts, LLC. (Startup #1 - Plant
idled 9/07) (Loudon, TN)
Microbiology Lab Supervisor / Phage Lab Supervisor / Plant Fermentation
Microbiologist
I served as the plant microbiologist, microbiology lab supervisor, and
phage lab supervisor at Dupont, Tate & Lyle Bioproducts, LLC (DT&LB)
starting in August, 2005. Prior to my arrival at DT&LB the company did
not have any completed laboratories, lab/validation SOP's, or
microbiology lab personnel.
My accomplishments at Dupont, Tate &Lyle Bioproducts include:
1. Managing a staff of up to 6 laboratory technicians including hiring,
training, scheduling, and career mentoring.
2. Actively monitoring all fermentations for contamination and
microbiological growth dynamics.
3. Leading all contamination investigations within the company.
4. Creating all aseptic validation protocols for all fermentors, tanks,
addition systems, and headers.
5. I designed, implemented, and maintained all environmental monitoring
and plant sanitation programs for bacterio-phage, airborne
particulates, GMO, soil, bioburden/sterility of raw materials, waste
stream monitoring, and bioscrubber GMO discharge.
6. Working closely with a colleague in Dupont I co-developed and tested a
new, proprietary rapid phage detection protocol capable of detecting
environmental bacterio-phage in ultra-low concentrations.
7. Authoring all microbiology and phage lab SOP's, data sheets and
databases needed to successfully operate both laboratories.
8. Maintained and oversaw the TSCA inventory of culture (biocatalyst)
used to initiate the fermentation processes. I grew the biocatalyst
inoculum that was used to inoculate all fermentations.