JAMES D. LEWIS

**** ********* **

Carmel, IN **032

317-***-****

acv6q6@r.postjobfree.com

OBJECTIVE

To obtain an Process Safety or Process Engineering Managers position where master’s degrees and proven skills in engineering and sciences can be utilized.

EDUCATION

Master of Management (M.B.A.), Purdue University December 2003

Master of Business Administration, major in Management

Master of Engineering in Chemical Engineering, University of Louisville 1992

Thesis: Development of an Expert System for Specifying Separation Processes for Dilute Solutions.

Bachelor of Science in Engineering Science, University of Louisville 1990

Major: Applied Science

PROFESSIONAL EXPERIENCE

Braskem N.A., Marcus Hook, Pennsylvania

Process Safety Leader (PSM and HES) May 2014 to Present

Lead Coordinate Root Cause Program for Corporate initiatives for 5 plants

Complete Process Safety, RMP and Internal Compliance Audits

Coordinate Risk Management Program (RMP) across the sites.

Manage Change Management Program to ensure compliance with site and corporate directives across corporation

Coordinate process safety and process metrics for key indicators.

Lead PHAs with LOPA for multiple sites.

Develop and management Peer review and Technical Review process for PHAs

Process Engineering Manager January 2011 to May 2014

Manage technical process engineering group responsible for providing technical support to the Polypropylene manufacturing process. Four direct reports including three Senior Chemical process engineers and one controls engineer.

Manage Technical budget of $2.1MM

Manage change management system including update of MOC database and training of 100 employees in Change Management.

Lead Coordinate Root Cause Program

Manage Change Management Program to ensure compliance with site and corporate directives

Coordinate process safety and process metrics for key indicators.

Led site PSM program including leading PHA’s for 13operating units, Process Safety Information management, and coordination of PSM training for entire site

Eli Lilly and Co, Indianapolis, Indiana

Process Engineering Manager June 2000 to January 2011

Engineering Team Leader/ Flow Mentor in a Pharmaceutical production plant

Lead project to improve yield on pharmaceutical API by 25% increasing product value by 33%.

Developed PSM applicability screening for site use governing solvents including Methanol, Acetonitrile, 37% Hydrochloric acid and Morpholine.

Developed PSM pre-startup safety review tool for use in change control documentation.

Supervise three Consultant Engineers and three Associate Consultant Engineers.

Supervise three hourly engineering technicians

oProvide mentorship for technicians

oProvide Development plans and feedback for all direct reports

oResponsible for freeze-dryer equipment reliability, repair and scheduling

oCommunicating manufacturing schedules across teams

Led Eight (8) Process Hazard Reviews related to intermediates processing using HAZOP and What-if Methodology

Coordinate project planning and development for building interns

Lead/Facilitate all Root Cause Analysis related to intermediates processing using Fault Tree, 5 Whys, Pareto and other Methodologies

oImplemented improved RCA tool reducing Human Error Prevention by 25%

oImplemented improved preventive maintenance procedure reducing unplanned maintenance by 10%

Serve as the technical expert/support for installation and maintenance of new process equipment.

oLed installation of degassing system saving $150,000 in deviation costs.

oDesigned and implemented ejector system for buffer manufacturing reducing cycle time by 25%

Provide Project Management for implementing improvement activities for capacity (yield, cycle time, change over time/cleaning, etc.); product quality, raw material cost, emissions/waste loads, process variability and process safety.

oImplemented automated makeup of buffer systems providing reduced cycle time by 20% and improving yield on each buffer by 25%.

oDeveloped emissions modeling using Batchplus (Aspen) resulting in project savings of $250,000 per year in monitoring costs.

Understand process/unit capacity constraints and identify projects to prevent conflicts, including the development of project business cases/EVA analysis and process checkout and startup.

Ensure Equipment Qualifications are completed successfully.

oLed over 50 equipment qualifications for new or replacement installations

WITCO CHEMICAL COMPANY, Memphis, Tennessee

Senior Process Development Specialist 1997 - 2000

Senior Technical Specialist in Fatty Acid Plant. Coordinated task of process engineers to ensure goals of improved yield and productivity were met. Responsibilities include Wiped film evaporators, Hydrogenation reactions and Pilot Plant follow-up. Directed efforts of maintenance and production supervisors to facilitate improvements to sub-optimal processes. Key accomplishments include:

Facilitated and staffed Hazop teams including two revalidations and one Hazop PHA team.

Implemented yield and PSM improvements for Formaldehyde handling system.

Supervised Hazop team actions to reduce environmental impact and improve safety of hydrogenation reactors, high pressure splitting columns, and wiped film evaporator.

Conceived and designed process changes to increase yield through wiped film evaporator by over 10%.

GREAT LAKES CHEMICAL COMPANY, Memphis, Tennessee

Process Engineer 1995 - 1997

Process Engineer in THF polymer (polytetramethylene glycol) producing plant. Ensured process met quality, yield, and production goals. Manufacturing responsibilities include CSTR’s, batch distillation, decanting, and Molecular Sieves for solvent purification. Responsibilities included:

Conceived, designed and implemented scrubbing system on process vent to save approximately $10,000 month in raw materials.

Implemented PSM initiatives for products and raw materials covering use of hydrofluoric and hydrochloric acid

Directed efforts of operators during the startup of molecular sieve unit resulting in savings of $150,000 per year in raw material and utilities costs.

Optimized batch washing process to increase production capacity by 500,000 lbs.

MONSANTO CHEMICAL COMPANY, Pensacola, Florida

Manufacturing Engineer 1993 - 1995

Manufacturing Engineer in Maleic Anhydride producing plant. Directed area efforts to maintain ISO 9000 certification. Ensured process met quality, yield, and production goals. Manufacturing responsibilities include ISO-9000/Quality Coordination, gas absorption, solvent stripping, and solvent purification. Accountable for:

Conceived and implemented modifications to Solvent Stripping train to reduce solvent decomposition by $200,000 per year.

Directed installation of off-gas analyzers to reduce product loss in absorption trains resulting in a gain of $200,000 in production.

ROHM AND HAAS KENTUCKY, Louisville, Kentucky

Chemical Process Engineer 1990 - 1993

Process Engineer in plastic additive producing plant. Ensured process met quality, yield, efficiency, and productivity goals. Production responsibilities included emulsions handling spray drying, powder handling and bulk packaging. Key accomplishments include:

Facilitated packaging efficiency improvement team resulting in a decrease in packaging downtime from 780 hours per year to 300 hours per year through increased training and preventive maintenance.

Designed and coordinated replacement of powder conveying line with new conveying line increasing production capacity by 3 million pounds per year (approximately $3 million).

Implemented process modifications to improve efficiency of rotary particle screeners. Increased yield resulted in an actual gain of 1 million pounds per year of production.

Coordinated efforts of packaging operators to eliminate unnecessary changes of filter bags in 30,000 lb/hr dust collector. Reduced filter changes resulted in $45,000 per year savings.

Designed and supervised the modifications to a bulk packaging system to accept super sacks with packaging weights of 1000 to 2000 pounds.

Chemical Engineering Intern 1987 - 1988

SKILLS AND PROFICIENCIES

Kepner-Tregoe Problem Solving and Decision Making

SPC

ISO 9000

Group Skills/Teambuilding

Project Management

PSM

PHA with LOPA

Developing Process Specific Training (TTS)

Management of Change

Process Safety Management Audits

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