Stephen P. Hayden

**** ******* ***** ****, ********, TN 38135

901-***-**** actlqa@r.postjobfree.com

December 2012 to Present: Quality and Logistics Manager, Arkema Inc, Memphis, TN - Responsible for plant quality and inbound /outbound logistics performance for $40M+ plant. Maintain ISO 9001 certification and cGMP compliance while improving plant management systems. Manage internal audit program, corrective actions, and address customer complaints. Manage change control and validation for API product process. Ensure compliance with DOT regulations for over 3500 hazardous product shipments annually. Supervise four direct reports and two indirects.

Achieved 99.4% RFT product production and 98% incident-free plant-controlled deliveries

Completed ISO audits with no major findings. Integrated ISO 9001 and OHSAS 18001 management systems

Conducted root-cause investigations utilizing methods such as TapRoot and Apollo

Hosted customer audits, retained customers, and gained new customers to grow specialty product production

Developed plant electronic document management system

Developed and executed process, analytical, and computer system validations

Developed cGMP training and reduced errors on batch records by 50%

Developed HACCP plan and established food safety team for food grade product production

January 2008 to December 2012: Environmental and Quality Manager, Arkema Inc., Memphis, TN - Responsible for plant environmental and quality performance. Ensure compliance with environmental regulations including air permit, POTW permit, and hazardous and non-hazardous waste. Prepare and submit all required environmental regulatory reports and interface with regulatory authorities. Supervised three direct reports and two indirects.

Implemented first plant Title V operating permit and developed systems for compliance. Received CEO recognition for reduction of Title V deviations.

Prepared minor permit modifications and a renewal application proposing permit enhancements

Prepared response to FDA audit findings and developed risk assessment and action plan using FMEA methodology

Developed systems to ensure cGMP compliance to ICH Q7A API product requirements and remediate FDA observations. No FDA observations on following inspection.

Developed process-based internal auditing program for ISO 9001

March 2003 to January 2008: Principal Plant Process Engineer, Arkema Inc., Memphis, TN - Optimize manufacturing cost, quality, safety and environmental performance. Plan, develop and implement plant improvements to reduce cost, increase production, and improve safety and quality. Lead major risk prevention / process hazard analysis activities. Prepare quarterly technical report and network with central technology team. Team with Marketing and Research in new product and new application development and customer support. Support operations through auditing, observations, procedure development, training, and troubleshooting.

Developed a 15% debottleneck of the hydrogen peroxide process. Funded first phase for $1.2M and second phase for $2.8M.

Implemented first commercial production of a new peroxide for the cleaning market

Introduced new process hazard analysis methods and led PHAs for major portions of the plant

June 1996 to March 2003: Senior Lead Process Engineer, Atofina Chemicals Inc. / Sartomer Company, Channelview, TX - Reduce manufacturing cost and improve product quality in two specialty polymer units. Develop process improvements or new product installations through scope definition and funding. Supervise contract engineering groups during project design and installation. Plan and develop plant technical programs. Assist marketing and research with customer support and new product evaluations.

Developed and implemented process improvements to improve the quality of a copolymer for a new market, increasing annual income by at least $500K.

Resolved two longstanding quality problems in a polymer product line by optimizing process parameters and procedures.

Led teams focused on issues such as process improvement, plugging and product quality. The plugging team developed recommendations to eliminate more than $750K in downtime.

Led a team that redesigned plant laboratory operations and built a new laboratory resulting in >$200K/yr reduced laboratory expense and improved service.

Conducted feasibility analyses for new product production.

Coordinated technical programs with the host company’s management in an owner/operator environment.

November 1990 to June 1996: Senior Process Engineer, Monsanto Company/Flexsys America, Nitro, WV - Ensure efficient operation of the specialty products units. Analyze process operations and identify and implement improvement opportunities, including capital projects. Conduct plant trials to demonstrate project benefits. Monitor operations and troubleshoot problems. Participate in safety and environmental initiatives and business teams.

Identified sources of contamination in a specialty chemical process and executed a $250K capital project to purify the product resulting in securing a new customer with potential first year sales of $800K.

Demonstrated changes to a polymer product line resulting in introduction of a new product with first year sales of $170K and performance improvements for an existing product that addressed customer complaints.

Developed and demonstrated a yield increase for an existing specialty chemical process resulting in annual savings of $65K.

January 1985 to November 1990: Project Engineer, Frito-Lay, Inc., Corporate Process Engineering, Dallas, TX - Develop process improvements or new product processes using pilot plant or semi-works tests and transfer the technology to the first manufacturing installation. Develop project economics and evaluate rollout opportunities. Design and install the first manufacturing demonstration and assist engineering group with subsequent installations.

Designed, supervised and started-up two new process equipment installations in manufacturing plants to increase capacity and reduce manufacturing cost resulting in roll-out to at least six other plants.

Conducted designed experiments to improve product quality by identifying sources of variability and optimizing process conditions.

Developed process conditions for producing a new product with existing plant equipment resulting in a national rollout of the process.

Master of Business Administration, The University of Memphis, 2006

B.S. Chemical Engineering, The Ohio State University, 1984

Registered Professional Engineer, state of West Virginia

ASQ Certified Quality Auditor

Contact this candidate