Project Manager/Process Engineer

Michael P. McDonald

Project/Process Engineer

Ph: 740-***-****

SUMMARY OF QUALIFICATIONS

A highly accomplished professional with expertise in project management, new plant planning

and implementation, research and development, procedure documentation, process optimization,

operator training, product development and improvement, and customer relations. Background

includes managing specifying and installing the 2 largest tandem lines producing P.E. foams in

N.A. The lines were installed on time and on budget producing the products the team designed

the lines to do. Able to resolve mechanical and formulary issues while supporting sales,

managing local maintenance teams, retraining local staff, and setting up SOPs.

Known for training and challenging others to accomplish set goals, evaluating plant abilities and

developing product specifications to meet growth and productivity objectives, and resolving

customer issues with their satisfaction as a priority. A fast learner able to adapt quickly to changes

in the work environment, with a personal motivation to plan and execute work to ensure a positive

impact on a company through discipline, knowledge and unfailing management skills.

Key Strengths:

Mechanical Engineering •Technical Lead • Product Development • Project Management •

Problem Solving

Leadership Skills • Team Building • Team Management • Training & Development

Analytical Skills • Quality Control • Planning / Coordinating

PROFESSIONAL EXPERIENCE

Contract Engineering – 2012 – present

• Worked with reclaim operations

• Resolved processing issues by establishing S.O.P.’s

• Troubleshoot down stream equipment water ring pelletizers and strand systems

• Created set-up conditions for materials being processed and trained operators on best

methods

• Resolved cooling tower problems and extruder issues

DIAB Inc. – R&D Engineer, Operations Product Owner

2010-2012

• Developed a new resin and 4 new products in the last 2 years, establishing set-up

conditions to run all products that were produced.

• Conducted trials here and abroad to develop basics used to reformulate and enhance

product properties.

• Trained operators on extrusion fundamentals and unit operations.

• Maintained the test lab and data bases dedicated to this unit of operations.

• Established and published product properties for F products globally.

• Resolved issues with internal and external customers regarding properties and end uses.

• Worked with external test laboratory to validate product properties for use in the

Aerospace industry.

Michael P. McDonald

Page Two

C – TEC – Instructor

2009-2010

• Taught adult students basic wiring principles.

• Trained students about basic troubleshooting of motor controls and circuitry.

• Taught students on basic hydraulics associated math/formulas and equipment alignment.

• Trained students to write basic PLC code for sequential control of machines.

Sealed Air Corp – Project Manager

2007-2009

• Managed teams to specify and purchase equipment for a new production facility, sizing

the extruders and specifying the criteria for the design of a new chiller system and bulk

blowing agent system to handle the anticipated load of the entire plant. Purchased a new

feeder and vacuum system to distribute resin as needed throughout the plant. Provided

the scope of the thermal oxidizers system to utilize heat from the exhaust stack

maintaining the elevated temperature required for the warehouse and the design of the

capture system feeding it to severely reduce the natural gas costs required to fire it

(saving approx. $15K/mo).Worked with all trades to modify the building to install

plumbing, electrical, and installed equipment as it arrived. The new facility was designed

to produce 70% of America’s daily use of foamed packaging materials.

• Developed and trained production line Operators on the use of Start Up and Run check

lists for use before starting the line, performance once the line was running, as well as

troubleshooting problems when they occurred.

Wise Industries Inc. – General Manager of Extrusion

2005-2006

• Worked with internal and external customers to develop new products

• Managed day to day operations of extrusion department

• Interfaced with sales and customers to resolve issues and mine data for new applications

Pactiv Corp. – Senior Product Development Engineer / Process Engineer /

Capital Project Manager

1997-2005

• Managed teams in the specifications and purchase of equipment for a new plant, sizing

the extruders, plant layout, expanding a chiller system, augmenting a vacuum system to

distribute resin throughout the plant; and worked with all trades to erect the building,

install plumbing, electrical needs, and installation of production machinery that resulted in

an on time delivery of a $10M budget.

• Maintained optimal operating conditions for all plants by resolving problems, restoring line

operations when problems occurred; and improved relationships with plant operators by

opening up communications, minimizing down time and optimizing the efficiency.

• Conducted production trials designed to identify problems with a polymer extrusion line.

Identified and documented best in class conditions, trained operators on defined

procedures and troubleshot, resulting in a 15% reduction in scrap and the training of all

personnel on procedures in sister plants.

• Designed dies to improve yields and product tolerances, extending trial findings to 2

additional company plants that resulted in a 10% improvement in production yields

across all plants and product lines, and improved customer satisfaction.

• Developed new classroom training module for plant operators that covered sequential

process operations, railcar unloading (vacuum systems), extruders/feeders (screw

design, basic extrusion theory, testing), downstream equipment (cure times), and finished

product properties used in all plant locations.

• Met with external customers to identify and resolve quality issues. Identified root causes

and worked with plants and customers to optimize each process. Modified the recipe and

met customer needs, retraining a $200k per year customer and becoming known as the

authority or “go to” person for the extruded plank and lamination lines.

Dow Chemical R&D – Senior Research Technologist / Market Development Supervisor /

Capital Project Manager / Waste Reduction Team Manager

1989-1996

• Conducted trials to improve polystyrene board forming process. Developed and

designed a forming apparatus to apply eco-friendly and less expensive “blowing agents”

used to reduce costs, allowing the company to retain a competitive sales position in

Europe.

• Maintained a research pilot production line that supplied global Ethafoam products

(polyolefin’s) that evaluated various resins for new products and enhanced the properties

of existing products, resulting in $1M per year in savings and new product development.

• Revived a shelved product by evaluating the existing polymers (polypropylene) based on

historical data and customer input, trialing new resin blends to identify best mix,

reformulating to produce a new product that allowed the company to be the first to enter

the polypropylene “boogie board” market valued at $500k per year for the company.

Additional Experience: M&L Oil and Gas Well Drilling – Production Engineer

1979-1989

EDUCATION

Franklin University – BS, Mechanical Engineering

Central Ohio Technical College – AS, Mechanical Engineering

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