Manager Project

Deborah Shaw

*******.******@*****.***

Experienced Chemist/Engineer with diverse experience in chemical manufacturing for 25+ years. Strengths include Manager of OSHA PSM regulated production areas, Process Development including scale up from Process Lab to Production, along with providing technical support, ISO/PSM/SHEQ audits & experience in Analytical/Quality Control. Project Management experience includes new products and process development/improvements for Fortune 100 companies & working successfully with customers.

Experience:

Benjamin Moore & Co., Pell City, AL

Resin (Polymer) & Low Flash Manager Jan 2014-Nov 2015

Maintain the P&L for Resin Production Plant maintaining all manufacturing costs below budget and below target. In 2014 decreased overtime by 35% with a decrease in CPG by $0.09. In 2015 increased GPMH by 20% & decreased overtime by 37% with Quality @ 100% in-spec.

Lead/Coach over 30 Operators in two OSHA PSM regulated production plants: Polymer and LF (solvent/epoxy) Plant

No Lost Time Injuries in Resin or Low Flash Plants

Prioritize daily production schedule to meet customer demands

Write/Update Standard Operating Procedures (SOPs) & perform PSM required training for requalification & skills demonstration

Write & submit MOC’s (Management of Change), participate in the reviews/approvals, prepare MOC’s for close out

Close out new MOC’s and ensure action items are closed in a timely manner, including PSSR’s

Work with Corporate Engineers to implement PSM programs & improvement projects

Assist Corporate Chemists with introduction of new polymer products to Production

Assist Corporate Chemists/Engineers with scale-up of existing products due to increase in customer demand

Work with Corp. Engineers & Contractors on installation of new equipment in Polymer and Low Flash Plants

Ensure Contractors have required permits such as safe work, line break, confined space & hot work permits, as required

Participate in Kaizen events & perform monthly 5S audits of different production areas within the Pell City site

Participate in PHA revalidation & close out associated action items

Ensure Operators & Leads in LF Plant were using Aptean software correctly for determining OEE for the line

Perform and participate in incident investigations and Root Cause Analysis (RCA) for PSM areas

Utilize Six Sigma 5-Whys for the RCAs

Work with EHS Manager & Operators to close out incident investigations in PSM areas

Completed open action items from internal PSM/PHA audits, from several previous years to present

Henkel Corp. – Adhesive Technologies, LaGrange, GA 2011-2014

Polymer Production Manager (2013 - 2014)

Managed weekly requirements for Polymer Production working with Planning/Scheduling to meet the goals

Supervised 4-5 Reactor Operators to produce acrylic polymers via emulsion polymerization in PSM regulated plant

Customer liaison for toll customers on new & existing products

Lead & participated in PSM, PHA, Risk Assessments and RCA’s for the site, along with ISO/SHEQ Audits

Utilized Six Sigma 5-Whys for the RCAs

Wrote & submitted MOC’s and participated in the reviews/approvals, along with closing out action items

Assisted with EH&S Regulatory reports & monitoring requirements, including regulatory agency visits

Purchased equipment and supplies for the Polymer Plant

Chemical Process Engineer (2011- 2012)

Project Manager for several new products & processes of emulsion polymerizations

Customer liaison for toll customers on new & existing products

Successfully planned, executed & coordinated the scale up of new products from R&D to Production

Facilitated increase in Polymer Plant production from 5 million lbs. to 9 million lbs. per year

Increased external customer production/satisfaction from 780,000 lbs. to about 3 million lbs. per year, in 7 months

Updated Costing for toll customers in SAP with Finance Department Manager which resulted in higher revenue

Technical support for Production with troubleshooting, process improvements & new processes

Developed/improved SOP’s and Work Instructions (WI/JSA)

Lead Kaizen teams for various processes to improve production & determine/monitor OEE for all site processes

Worked with Maintenance Department & Operators to develop new downtime report for determining OEE for all lines

Lead & participated in PSM, PHA and Risk Assessments for the site along with ISO/SHEQ Audits

Completed open action items from internal PSM audits for several previous years

InChem Corporation, Rock Hill, SC 2009-2011

Global manufacturer of specialty resins, such as phenoxy resin, and custom manufacturer of specialty chemical products. Business markets are coatings, inks, adhesives, plastics and composites.

Senior Process Chemist

Project Manager for several new products & processes such as coatings, polymerizations, polymer additives, anti-oxidants for plastics, herbicides & pesticides

Customer liaison for Corporations on new products/projects

Coordinated all aspects of new process introduction from QC lab, R&D lab to Pilot Plant into Production

Technical support for Production with troubleshooting, process improvements & training Operators on new processes

Wrote/Updated SOP’s for new/existing processes

GC method development & VTA Thin Film Evaporator for customer projects

Kao Specialties Americas LLC (KSA), High Point, NC 2007-2009

Business markets are Toner Binder, Oleo Chemicals, Aroma Chemicals, Custom Manufacturing, Surfactants, and Construction.

Product Planning Coordinator (Project Manager) on Business Development Team

Project Manager for new product design & development along with transfer products

Liaison for all departments including Purchasing, EH&S, Engineering & Operations to introduce processes from R&D to Production

Developed process flow diagram (PFD) for new product introduction with the Quality Manager, involving all departments

Performed financial analysis, using SAP & BW, to determine marginal income (MI) on products to improve portfolio management, assigned to me by Site Manager

Updated master data in SAP for various products

Maintained all products for Product Life Cycle Management with Corp. headquartered in Japan

Maintained database & all legal contracts of contractors/customers

Maintained all documents, including tonnage report, for suppliers/customers for REACh

Internal Auditor for ISO/Responsible Care Audits - Developed & wrote ISO procedures

Assisted EH&S with Regulatory reports such as SARA 313, Tier II, NAFTA certificates, TSCA, FIFRA & MSDS’s

Participated on HAZMAT Team, Safety Inspections Team, & community response team drills

DanChem Technologies, Inc., Danville, VA 2005-2006

Custom manufacturer of fine and specialty chemical products. Business markets are Paints, Coatings, Personal Care, Food Additives, Pharmaceuticals, Textiles, and Electronics.

Senior Process Chemist (Project Manager)

Customer liaison for Fortune 100 companies & other corporations for new products/projects

Coordinated all aspects of new process introduction into Production & trained Operators on new processes

Technical support for Production with troubleshooting, process improvements & new processes

Wrote/Updated Standard Operating Procedures for new/existing processes

Performed cycle time analysis on critical processes

Assisted QC Lab w/troubleshooting/repairing instruments such as HPLC’s and GC’s

Served as Production Supervisor, Plant Manager, Process Development Manager, as necessary

Supervised 8-12 Operators & Lab Technicians, as necessary

Syngenta Crop Protection, Bucks, AL 2002-2005

Chemist

Operated a centrifuge, crystallizer and/or charged raw materials for reworking major herbicide in Pilot Plant

Successfully reworked off-spec product in Pilot Plant valued at $39.6 million USD

Provided Technical plant support to Engineers and Operators for major herbicide product

Assisted Ph.D. Chemist in R&D Lab with projects to isolate and identify impurities with GC, HPLC, NMR, LC/MS & RSST

Set-up and performed lab scale batches to assist with troubleshooting Production processes

Ciba - Polymers Div., McIntosh, AL (presently Huntsman Advanced Materials) 1988-2002

Production Planner/Scheduler (2001-2002)

Planned monthly schedules for Production in Specialty/Standard Resins Lines & at Toll Sites

Participated in Supply Chain Management monthly meetings

Worked with Corp. Supply Chain Managers & Line Engineers to plan and schedule production to reach goals

Development Chemist (1993-2001)

1993-1996 Chemical Div. Fluorochemical BU Firefighting Foams, Paper Coatings & surfactants;

1998-2001 Polymers Div. Waterborne Coatings & Solid Resins

Recommended & successfully introduced process improvements for existing processes (Decreased Gardner Color from 9 to <2) on major paper coating product

Developed new GC methods for new processes & improvements for existing processes to detect Acrylamide (<0.1%)

Developed and scaled up processes from Research to Pilot Plant into Production

Provided Technical support for plant introductions of new processes & improvements to existing processes

Prepared cost estimates, feasibility studies, mass balance on new processes

Prepared Industrial Hygiene Plan for the lab

Lead & participated in Process Hazard Analysis (PHA’s)

Analyzer Coordinator/Chemist (1996-1998) Chemical Division Fluorochemical Business Unit

Maintained all instruments, which included GC’s and on-line analyzers

Provided analytical support/training to Operators on various analyzers

Provided on-call support for analyzer issues along with the Central Analyzer group

Shift Chemist (1988-1993) Chemicals Division A&QC & Brightener Business Unit – Chemical Brighteners & Paper Yellow Dyes

Analyzed raw materials, intermediates, & final products for composition and purity

Trained Operators on QC tests such as GC and HPLC along with wet chemistry tests

Participated on HAZMAT Team

Member of first team to set up A&QC lab in the production area of a business unit

Southern Company – Alabama Power Co. – Barry Generating Plant in Bucks, AL 1986-1988

Chemist

Assisted with chemical cleaning at Barry and Greene Co. Plant

Inspected boilers after major shutdowns for maintenance

Operated & maintained 3 water treatment plants which included a flocculator and cation/anion resin vessels

Tested and maintained the water chemistry for 4 Coal-fired units and 1 Supercritical unit

Pulled routine transformer oil samples & shipped to Corporate lab for testing

Scaled coal barges for determining the amount on coal on the barge & checked for water leaks

Ran analysis on coal and prepared samples to ship to Corporate lab for further testing

Education:

Master’s in Business Administration – University of Mobile (formerly Mobile College); Mobile, AL

B.S. Chemistry and Biology – Mobile College; Mobile, AL

Recognition and Performance Awards:

Outstanding Young Woman of America

American Academy of Distinguished Students

Lewis D. Crane Pre-Med. Scholarship

Sam and Carrie McDonald Scholarship

Biology Area Scholarship & Alabama

Baptist Convention Scholarship

Ciba – Special/Quality, Round of Applause & Ciba Plant Team of the Month Awards

Special Skills:

GC/MS, GC, HPLC, TLC, AA, FTIR, XRF, ICP, NMR, Mettler RC1, RSST and DSC, UV/Vis., Particle Size Analyzers, VTA Thin Film Evaporator along with Wet Chemistry, SAP, Microsoft Office (Word, Excel, Power Point, Outlook), Lotus Notes, Visio, LIMS, ChemStation, CAMILE, SPC, PSM, Leader for PHA’s & RA’s, Pre-Safety Start-up Review (PSSR), PFD, E&MB, MOC, Failure Mode Effects Analysis (FMEA), Root Cause Analysis (RCA) with 5-Whys, Leadership skills, Communication skills, ISO Auditing, 5S and Kaizen, Lean Manufacturing, OEE, OSHA 10 hr. General Industry Certificate, NAFTA & Harmonized Tariff Certificates, Successfully work with an internationally diverse group of Chemists/Engineers

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