Manager Maintenance
Resume:
***************@*****.***
HASHIM, USAMA M
PROFESSIONAL
EXPERIENCE
SITE ENGINEERING & MAINTENANCE MANAGER, CIRCLEVILLE, OHIO (DuPont)
Responsible for all site capital execution for all four business units. Ensure we follow a rigorous detailed process that executes all work based upon the demands of the operating areas from design phase to process start up, over $16MM of capital work scheduled for 2015. Completed restructuring process of Business Centered Maintenance, which led to $790K fixed cost savings impact to site. Manage over 170 individuals with 11 direct reports ($18MM fixed cost budget).
SITE MAINTENANCE UNIT MANAGER, CIRCLEVILLE, OHIO (DuPont)
9/2013 – 1/2015
Responsible for managing all maintenance functions safely from planning to execution of all shutdowns ($15MM fixed cost budget). Kicked off restructuring process to for maintenance integration into operations to better serve the four business units at the site (Business Centered Maintenance). Also had line responsibility for Powerhouse operations, Contract Administration & in-house Contractor maintenance organization. Ensured that each layer of the team incorporated the right level of knowledge transfer and development. Also drove the introduction of the multi-craft mechanic concept for the entire organization. Responsible for over 140 individuals, with 10 direct reports.
CPM FINISHING AREA MANAGER, CIRCLEVILLE, OHIO (DuPont)
2/2010 – 9/2013
Led the restructuring efforts to further integrate contractors into the area, where they are now fully trained in running slitting assets. Responsible for 45 DuPont & 85 contract personnel ($10MM fixed cost budget). This transition allowed us to save approximately $800M per year from the area fixed costs. Improved final slitting yields from a base of 70% to 83%, 1% of yield has a value of $600M (graph below). Results have been sustainable after I have left role as well. Ensured that area met Clean room 10,000 standards to meet our customer’s strict quality expectations.
PVFM COATING AREA MANAGER, BUFFALO, NY (DuPont)
10/2007 – 2/2010
Responsible for transforming a pilot scale facility to full plant capability for the PFVM business unit. Utilized multiple continuous improvement initiatives such as Six Sigma, DPS, Kaizen events and Value Accelerators. The team was able to ramp up production from about 5 tons/month to approximately 90 tons/month in less than 12 months. This generated the additional capacity required to ensure we retained customer share while the new Tedlar® line was being built. During that assignment my job scope grew to include the slitting operations for Tedlar as well. I had line accountability for 5 exempt & 45 non-exempt employees ($6MM fixed cost budget).
SIX SIGMA BLACK BELT, BUFFALO, NY (DuPont)
6/2006 – 10/2007
Worked on projects that improved film flatness, yield & productivity. Generated Over $3MM in savings to the business. Also helped support the PVFM coating line as business ramped up production capability.
AREA SPECIALIST, CIRCLEVILLE, OHIO (DuPont)
2/2004 – 6/2006
In that role I worked on improving safety behavior, quality performance, driving equipment reliability, & operational discipline for the manufacturing organization (HHP). During that assignment I was able to achieve a 29% reduction in DMAc overexposure, by conducting detailed analysis on the reasons why operators were getting exposed. By understanding the root cause for failure we were able to implement sustainable control plan that paved way for further improvements. I was also charged with improving operational discipline for all operations on the Casting lines, specifically K3 our newest asset. The operators lacked a defined protocol for monitoring & responding to critical process variables that impact key production and quality metrics. By utilizing teamwork we were able to develop a robust process monitoring protocol that defined the critical variables & frequency of monitoring. That work was leveraged to the other assets.
FIRST LINE SUPERVISOR, KAPTON, CIRCLEVILLE, OHIO (DuPont)
2/2002 – 6/2004
In this role I had responsibility for one of the rotating shifts in the Finishing area (15 DuPont & 10 contract employees), while still maintaining line responsibility for my previous assignment. I also led the team on SAP Go live. One of the main issues the area experienced at Go Live was the interface with SAP, which did not function properly. I was the person charged with defining what the issues were & developing a plan to implement the required changes. Part of my scope of work was to ensure reliability of the system which required extensive testing over a 3 month period. This allowed us to develop the protocol that is still used today to any upgrades to the interface with SAP.
FIRST LINE SUPERVISOR/PROCESS ENGINEER, CIRCLEVILLE, OHIO (DuPont)
10/2000 – 2/2002
I was the day supervisor responsible for safety, production & maintenance of the Kapton Coating & Film Stabilization assets. I lead projects that focused on improving operational discipline, reliability & yield performance.
FIRST LINE SUPERVISOR/PROCESS ENGINEER, BAYONNE, NEW JERSEY (CasChem)
2/1997 – 9/2000
Led the operations startup of a 4MM Sebacic Acid plant, participated in PHA’s, developed training packages for operations & maintenance. Helped develop all procedures including the technology manuals for the process. Was integral in the check-out process by developing process milestones to ensure safe and efficient start up.
FIRST LINE SUPERVISOR, HICKSVILLE, NEW YORK (Ruco Polymer)
1/1996 – 2/1997
I was the day supervisor responsible for safety & production of all assets at the facility. I also managed all bulk chemicals including shipping, receiving, & analysis of raw materials.
EDUCATION
MANHATTAN COLLEGE, BS CHEMICAL ENGINEERING
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