Plant Engineer

Tony L. Henderson

*** ********** ***** *****, **** 50036 515-230-7500h 515-230-7500c **************@*****.***

SUMMARY

Experienced in Project-Process and Facilities Management. Demonstrated success in Lean Manufacturing and Six Sigma. Self-starter with strong, demonstrable skills in leadership, people/soft skills, analytical skills, academic excellence, and conceptual thinking. Detail oriented, highly organized, flexible, and able to prioritize with the ability to multi-task. Excellent computer and interpersonal skills, strong verbal and written communication skills. Excels at negotiating, budgeting and identifying cost savings. Goal oriented with the strong ability to meet time lines and objectives as needed on multiple tasks."

PROFESSIONAL EXPERIENCE

BOEHRINGER, FORT DODGE, Iowa 2010-Present

Project Engineer Management

Accountable for projects. As well as all plant operations. Use MS Project, Excel, PowerPoint, Word and Outlook .

Directs and coordinates activities to ensure project progresses on schedule and within budget High level of Prioritization skills and Focus on projects used to achieve goals .Provide daily and weekly status reports-develop, review and obtain confirmation of financial and project delivery schedule activities of design and construction as they relate to all disciplines involved and report to top management.

Assure that the design and construction teams comply with the contract approved design agreement and established budget- Ensure contractor (s) captures and maintains project as built redlined project control documents (P&ID, etc).

Responsible for the specification, design and equipment implementation in FDA and USDA pharmaceutical production facilities.

Extensive experience with compendial utility installation and modification of existing systems.

Management and engineering of facility and utility renovations in compliance with cGMP and USDA requirements.

Formulation of project documentation including User Requirements, Functional and Design Specifications. Change control assessment and documentation.

Extensive interaction with quality assurance, production units and maintenance in the formulation and execution of projects.. Experience in a Lean manufacturing and development organization.

I maximize efficiencies of plant operations while optimizing plant run time, troubleshoot and identifies process needs to maintain production levels, is accountable for all plant operations, production goals, ensures compliance of environmental and health & safety needs facility.

Capital projects as well as expense projects.Manage project Timeline, work with plant personel and consultants.

Specifiy capital equipment performance and design criteria.

Lead commissioning and validation of equipment and areas.

I Have Effective interpersonal skills with a diverse group of individuals at all organizational levels

Proficiency in relevant computer software and programs,AutoCad associated with Engineering.

Excellent written and verbal communication skills.

Attention to detail and commitment to customer service

Obtaining bids, coordinating construction projects for facilities and/or equipment repairs, negotiate contracts, discuss projects.

Abreast of new developments in Engineering fields that pertain to facilities, utilities, and various other operations throughout the plant.

Scheduling capital activities to meet production needs. Coordinating construction activities to minimize impact on production

Communicate with the facility on all levels thru a lot of different ways, PowerPoint, email, and presentations.

Develop global performance measures and report against performance targets.

Developed short term strategies and long term vision for Boehringer-Ingelheim EHS compliance driving for EHS excellence.

BALL PLASTICS CORPORATION, Ames, Iowa 2002-2010

Senior Process Project Engineer/ Operations Director of Facilities/EHS

IN charge of 6 facilities and there engineering staff This includes all changes and issues to Hvac and there mechanical systems. More specific responsibilities include engineering/process design, project coordination, determining and writing specs. Control wastewater systems.

Global EHS leader for seven plants Knowledge of regulatory EHS and product compliance .

Strong ability to apply inquisitive, analytical thinking to problem-solving scenarios

“Hands-on” leader with the ability to direct and supervise, as needed

Project Management and negotiations on an on-going basis, Statistical process control, And Root cause Analysis. Seven years experience in 6 industrial plants, process plants, operating boilers, turbine generators, pumps, fans, conveyors. Cooling Towers.

Establish and guide the plant Safety Committee to facilitate the implementation of pertinent policies and procedures for the assigned operations. Ensure the committee is involved in Job Safety Analyses, the behavior observation process and other hands-on activities.

Review required regulatory reports prior to submission, Assist in auditing plant status and progress. Ability to collect, statistically analyze and interpret data & establish corrective and preventative actions

Maintains and adjust project schedule as necessary to ensure good progress and meet all completion dates. Provide weekly and daily updates of progress on the schedule to upper management. Monitoring all vendors, contractors and subordinates, for their compliance to the schedule and take corrective action.

Assist senior leadership in development of long and short range planning, policies, programs and objectives related to the efficient and effective operation of the business.

Assist and improve design of new components and redesigned components, to improve quality, function, performance and reliability while maintaining cost, manufacturability, and agency compliance.

Track and Document Trend and Root Cause Failure Analysis as it relates to plant safety, operation and reliability.

Experience with Maintenance Management Systems such as Cmms systems and bms systems and 7 I have used Maximo some.

Knowledge of maintenance procedures for centrifuges, drying equipment, boilers, cooling towers, chillers, air compressors, pumps, valves, electrical circuits and 4-20 milliamp instrumentation

Provide coordination and assist plant operations in environmental compliance by ensuring proper record keeping of our requirements. Responsible for reporting obligations as required by local, state, federal and corporate requirements from a BU perspective.

Named to corporate role operating out of the Ames facility. AS the Operations Support Director of Facilities. Communicated effectively with people in all areas of the division. Assisted plants with enhancing systems including quality, preventative maintenance, line / tooling changeovers, major equipment overhauls / installs and overall efficiency improvement. Assist customers with container run-ability issues thereby improving their bottle-handling equipment.

• Implemented a division wide scrap tracking program; this allowed the plants to focus their efforts on the area with the highest return.

• With the assistance of the Process Engineers implemented a PM and rebuild program. Saving over $500K and improving efficiencies in some plants by 10%.

• Managed a line improvement project at a west coast customer location, improving line efficiencies by over 10%.

AGP, Eagle Grove, Iowa 2001-2002

Maint. Sup/ Reliabilty/ Engineer

Accountable for production goals and lab operations. As well as all plant operations. Manage a team of eleven people.

1years experience in an industrial plant, process plant and power plant, operating boilers, turbine generators, pumps, fans, conveyors, We had coal fired boilers for our turbines.

Tracked daily and weekly budgets and production of the extraction facility

Insure that all city, state and county, regulations are being met at all times

Knowledge of maintenance procedures for centrifuges, drying equipment, boilers, cooling towers, chillers, air compressors, pumps, valves, electrical circuits and 4-20 milliamp instrumentation

Strive for maximum efficiency in plant operations, optimize plant up time or runtime and minimize all plant downtime. Grain handling--handling incoming, binned, and outgoing grain.

Technical, financial & operational expertise sampling and accurately grading all incoming and outgoing grain.

Ensure that all plant policies are implemented and followed

Maintain and enforce all safety programs and procedures.

Worked with outside contractors and consultants changed electrical prints and drawings as needed to update and correct.

Facilitate communication between departments. Attend product, merchandising, and meetings

Present capital request justifications for the plant manager, communicate with organization at all levels.

Communicate production performance numbers to the plant manger as needed.

Knowledge of reliability centered maintenance, planning and scheduling.

Predictive maintenance done, ( infared, vibration, oil testing auto lubrication, Mce).

HUMBOLDT SAUSAGE, Humboldt, Iowa 1999-2001

Plant Engineer/Maintenance Manager/EHS

Project Engineer for expansion. Working on six million-dollar expansion and improving production Developed and monitored plant procedures

Plant Maintenance Manager for 12 employees

GMP audits, Lean Manufacturing facility

Layout and design new production lines/areas

Refrigeration and boiler design

Research/provide justification for new equipment

Worked with outside contractors and consultants

Setup PSM Program; PIDS

Setup PM Program to monitor maintenance activities

Responsible for pre and post-audits for inspections

Safety Director for the Division/ Environmental Director

Kept environmental records and did HSE projects

FIRESTONE TIRE AND RUBBER COMPANY, Des Moines, Iowa 1985-1999

Process Engineer and Manager

Developed and designed new line layouts; worked with Kaizen aspect and Lean Manufacturing ideas to keep in tune with design

Managed a team of 14 people and evaluated on a yearly basis.

Monitored and directed the plant in control and testing of wastewater and facility requirements; made changes as needed to HVAC systems, chillers and boilers from controls to any issues contracts to plant union people

Selected as plant coordinator for ISO9000 Certification project; brought the plant to certification in ISO9000 and also under QS9000; became overall engineer to direct the plant in qualification of these programs

Researched, developed, monitored and maintained all projects from start to finish until perfected in functions as well as cost effective

Managed a test lab for quality .Managed testing issues and risks as well as overseeing the defect management process and test results, reporting, metrics and other types of testing communication.

Worked on multiple tasks and lean manufacturing operations to reduce cost and increase productivity. Conducting Process Capability studies.

Received award for Contributions for leading the way to Certification to ISO 9000, QS 9000.

SWIFT AND COMPANY, Des Moines, Iowa 1979-1984

Maintenance

Developed and designed new line layouts; worked with kill floor rendering and processing.

Monitored and helped the plant in wastewater and facility requirements; made changes as needed to HVAC systems, chillers and boilers from controls to any issues in plant.

Worked in processing packaging and variety meats and coolers on all phases as needed

Worked on refrigeration and blood centerfugies off and on as needed.

Rebuilt the westfalias in fat room and fabricated parts and conveyor fixes as needed.

Did boiler inspections and cooler inspections.

Fixed flooring and roofing as needed.

EDUCATION

TPC Engineering School, Chicago, Illinois 1983 -1987

Mechanical Engineering

Des Moines Area Community College 1981-1983

Business, Computer Integrated Manufacturing, Business Law and Chemistry

Additional Courses taken during career

Windows AutoCAD, PowerPoint

Advanced Design Project

Material Resource Planning

Thermal Systems Computer Integrated

Manufacturing

Just in Time Certificate

Master Production Scheduling

Manufacturing Resource Planning

Business Law

Kaizen

5S Training

Direct Controlling and Managing

Forklift Class “Train the Trainer”

Lean Manufacturing

Siemens Q Can Designer

G E Betz Cooling Water

Engineering Training

Treatment and Operation

Six Sigma Green Belt

Machine Guarding

Networking Using Ethernet

Key Link to Productivity I &II

Advanced Supervisory Techniques I & II

Principles and Practices of Management I & II

Communications in the real World

Project Layout and Plant Design Seminar

APICS Certification

RETA Trained and certified in Refrigeration

Osha 30

Performance Management Training

Osha electrical NFPA 70e

Mhs Safety Handling and Rigging Training

ACTIVITIES/HONORS

24 hour Emergency Responder Training

Worked closely with DNR on wastewater and pollution issues

Attended Seven Habits of Highly Effective People seminar

Member, American Society of Mechanical Engineers

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