Case Management Manufacturing Facility

Terry Carr

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

South Sioux City, NE 68776

Mobile: 316-***-****

Email: ******@*******.***

Seasoned EHS/PSM professional with a solid track record of delivering results in large volume manufacturing facility, chemical continuous and batch operations, composite manufacturing, team leadership, process/procedure improvements, incident investigations, and best practices. I possess a proven aptitude for understanding and troubleshooting chemical and mechanical processes, implementing process improvements and cost-cutting initiatives that improve an organization’s bottom-line results. I have consistently demonstrated the ability to work effectively with all levels of employees and direct reports. Looking for new opportunities to be a major contributor to the success of a solid EHS/PSM atmosphere.

Knowledge Areas

Developing/Implementing EHS and PSM Management Systems

OSHA PSM, EPA RMP, EHS 18 Month Improvement Plan, EHS Handbook, Housekeeping, Online MOC/PSSR and PHA Systems, Visible Safety Leadership, Online Incident Reporting and Corrective Action Tracking Systems

Extensive knowledge of EPA, OSHA, RMP, DOT, NFPA, ANSI, NEC, ASTM and ASME requirements applicable to business and industry

Development and management of Industrial Hygiene programs and testing

Development and management of Occupational Health programs and Medical Case Management (WorkCare)

Developing/performing EHS and PSM Audits and tracking Corrective Action Plans -Dakota

Developing/Implementing EHS and PSM Training

Area Improvement Team (AIT) and Workout Lite Facilitator

Accident Investigation/Root Cause Analysis

ISO 14001:2004 Certification

RC 14001:2008 Certification

OHSAS 18001:2007 Certification

Velocity Rapid Ergonomics Assessmet

Behavioral Based Safety (BBS) and Behavior Safety Technology (BST) – SAFE, SAFESTART, SafeLead

Human Performance Reliability (HPR) using Safety Behavior Observations (SBOs) – ProAct Safety

Contractor Safety Training and Selection – Abbottsfield, PICS, ISNetWorld, DISA

EPA Form R (TPI) and Pollution Prevention Progress Report (P2PR)

Section 312 of SARA Title III – Tier II Emergency and Hazardous Chemical Inventory

Title V Air Permitting

EPCRA Section 313 Chemical List

Member of Local and State Safety Councils

Member of Local County Emergency Management

Six Sigma / Lean and 5s Visual Systems

Kaizen and SMED (Single-Minute Exchange of Dies)

Professional Experience

12/2017 – 11/2023 CF Industries – Port Neal Sergeant Bluff, IA

Environmental, Health & Safety Manager

Reporting to the General Manager of the Port Neal site with responsibility for the Environmental, Health, Safety, Process Safety, Lab, contracted Security and contracted onsite Clinic at the Port Neal Nitrogen Complex. The EHS Department consist of forty individuals; 20 employees and 21 contractors.

Key Accomplishments

Rebuilt and improved the perception of the EHS Department with the hiring of eight highly qualified EHS professionals and fourteen contractors.

Lowered TRIR from 3.93 to 0 in 2018, 2019, 2020 and 1.0 for 2021, for 275+ employee facility

Three-year Safety Strategy with ProAct Safety (2021-2023): Prioritization of our safety actions and improved communication, advanced safety coaching for frontline supervisors using SafeLead, and Rapid Ergonomics Assessment for office and production areas.

Three-year Safety Strategy with ProAct Safety (2018-2020): Drove, leveraged and supported the implementation of an EHS Strategic Team with eight sub-committees to improve Port Neal’s overall EHS performance.

Major improvements in EHS procedures and documents, with key emphasis on the documentation of historical work practices and the actual work being done in the field.

Cultural shift where everyone owns safety and all departments work as a Team, supporting each other and EHS initiatives.

Developed strategy to build a high-level Emergency Response Team using existing site personal; consisting of initial onsite training from emergency response training companies and a local college, focused on annual refresher training with a strong emphasis on multiple drills throughout the year. Focused on four key areas of certification: Confined Space/Rope Rescue, Industrial Firefighting, Hazmat Technician and Emergency Medical.

Major focus on hazard identification with risk elimination or mitigation

Managed the challenging COVID-19 pandemic using many different technologies: Thermal temperature scanning, screening questions, face coverings, close contact logs, quarantines, PCR testing, proximity tracing tags and Rapid/PCR testing for contractors.

07/2014 – 12/2017 Koch Ag & Energy, LLC Wichita, KS

Director Health & Safety

Reporting to VP of compliance with responsibility for the Health & Safety of four Nitrogen Fertilizer plants and one natural gas fueled electric power plant. Compliance oversight for twenty-six Nitrogen Terminals in the US and eight International Terminals. Corporate staff of four safety professionals and indirect support for over twenty-five site safety professionals.

Key Accomplishments

Team Contracted and Implemented a third-party Medical Case Management Company

Team updated and created over sixty Health and Safety Documents

oHydro Blasting Standard, Occupational Health Standard, Emergency Response Standard

Interviewing and recommendation for the hiring of twelve Safety and Operations Professionals

Changing the culture from a very strong Compliance culture to a relations-based Risk Management culture

oReduction in the RIR to the lowest rate in many years

08/2012 – 07/2014 Solvay (Rhodia-Legacy) Baton Rouge, LA

Process Safety Engineer/Process Risk Analysis Leader

Reporting to Industrial/HSE organization with responsibly for the Process Safety Management Programs of two Business Units located in Baton Rouge. Eco Services consist of four units and produces Oleum and Sulfuric Acid; Aroma Performance consists of three units and produces Ethyl and Methyl Vanillin. Supported two Eco sites in Dominguez and Martinez, CA and an Eco site in Portland, OR. Also, supported a Specialty Polymers facility in Orange, Texas.

Key Accomplishments

Developed 5-year revalidation schedule for site’s fourteen PHAs (LOPAs)

Design reviews and PHA’s for major capital projects (LOPAs and/or WHAT-IFS)

Updated site Process Hazard Management Procedures (PHMP)

Developed site PSM and MOC training programs

PSM Audits and Safeguards Audits of Risk Reduction Credits (RRCs)

Root Cause of Medium or higher-level Process Safety incidents

Site Leadership Team and Training Improvement Team

08/2010 – 08/2012 Cytec Engineered Materials, Inc. Greenville, TX

Senior EHS Specialist (temporary assignment) / PSM Center of Competency

Responsible for all the environmental, health and safety policies, programs and procedures for Cytec’s largest Engineered Materials Site. PSM team member for Cytec Industries PSM group; responsible for developing training materials and risk reduction credits for the PHA methodology and assisting with other corporate PSM projects. This was a temporary assignment to train the new cluster Manager, before transferring in to a Corporate PSM role or EHS Manager of new manufacturing site.

Key Accomplishments

Completed training of new cluster EHS Manager

Process Safety Management (PSM) Site Coordinator / PHA Leader – HAZOPS using PHAWorks

Management of Change (MOC) Site Champion (Centurion)

Lead Corporate Auditor for Cytec Process Safety Management (Dakota)

Implemented online self-auditing program for Environmental and Process Safety Compliance (Dakota)

Design Reviews and PHAs/MHAs for major capital projects

Implemented Medical Case Management Process which eliminated a number of recordable incidents

Cytec Industries Standards Board member developed /updated standards on flammability, combustible dust and hot oil systems

Design Review Team member for Major Corporate Capital Projects / PHA Leader

6/2009-7/2010 MSC Southeast Technical College Winona, MN

Part-time EHS Instructor (approved by Cytec)

Trained area industries in safety related courses, conducted audits, ergonomic assessments and lean consultations through the college’s external learning program.

7/2007-8/2010 Cytec Engineered Materials, Inc. Winona, MN

EHS Manager / Product Steward

Responsible for all the environmental, health and safety policies, programs and procedures for Cytec’s oldest engineered materials site. I was responsible for developing and maintaining product MSDSs, regulation requirements and documents for TSCA and REACH.

Key Accomplishments

Meritorious Achievement Award in Occupational Safety (2007 & 2009)

Process Safety Management (PSM) Site Coordinator / PHA Leader – HAZOPs using PHAWorks

Management of Change (MOC) Site Champion

Cytec Industries “Chairman’s Safety Award” (2007 & 2009)

RC 14001:2008 Certification

Lead Corporate Auditor for Cytec Safety, Health & Emergency Response (SHER)

Peer Corporate Auditor for Cytec Process Safety Management

RC 14001 and ISO 14001 Auditor

Implemented online MOC/PSSR system (Centurion)

Cytec Cost Reduction Team for hazardous waste, major coast savings in MN and CA sites

Site Leadership Team

8/1980-07/2007 Philips Lighting Company Salina, KS

Six-Sigma Black Belt/ Safety Engineer

Continuous improvement projects using six sigma and lean tools and site training for all Green Belts. I was responsible for developing and managing all safety policies, procedures and training for the site. I also, assisted with air permitting, hazardous waste management systems and waste water treatment.

Key Accomplishments

Implemented and chaired the sites very successful Safety Committee

Developed safety training, auditing and industrial hygiene programs

Major guarding and OSHA compliance systems created

Philips QIC 2007 (Quality Improvement Competition)

Education

May 2002 MBA (3.90 GPA) Kansas Wesleyan University Salina, KS

May 1984 Associate of Technology: Chemical Engineering (3.55 GPA)

Kansas State University (Salina) Salina, KS

May 1982 BS Chemistry/Biology Kansas Wesleyan University Salina, KS

Professional Affiliation, Training and Continuing Education

Rhodia Risk Management Leader Training – two weeks in Lyon, France

Critical Task Analysis (CTA) Training

PHAST Introduction – DNV Software (Consequence Modeling)

Understanding & Controlling Electrostatic Hazards – Chilworth

Dust Explosion Prevention & Protection Techniques – Chilworth

Gas/Vapor Explosion Hazards – Chilworth

Evaluation and Selection of Electrical and Non-Electrical Equipment for use in Hazardous Areas – Chilworth

Chemical reaction Hazards - Chilworth

Member of the American Institute of Chemical Engineers (AIChE)

Member of the American Society of Safety Professionals (ASSP)

Hazardous Materials and Waste Management

Ionizing Radiation – Producing Equipment, Radiation Officer (RO)

Haz-Mat Technician / OSHA HAZWOPER

First Aid/CPR/AED (Instructor)

Basic Workplace Safety Certificate

Introduction to Loss Control

Forklift Train-the-Trainer

Peer Auditor Training (SH&ER, PSM)

Crisis Management

Manage direct reports and dotted line reports

Process Driven Comprehensive Auditing (ISO 14001)

Introduction to Occupational Health

Introduction to Occupational Safety

Fitness for Duty

Process Hazard Analysis: HAZOPs, LOPAs, WHAT-IFS (Primatech PHAWorks & SARA)

Safety Interlock Systems (SIS) – SIL Calculations

Behavior Safety Technology

RC14001 Internal Auditor Training

Air Quality 102

Spill Prevention Control and Countermeasure Plan (SPCC Plan)

Water Quality Permit: NPDES/SDS Permit

General Permit Industrial Storm Water Discharge

U.S. Geological Survey (USGS)

Community Emergency Response Team (C.E.R.T.) – Train-the-Trainer

Introduction to the Incident Command System (IS-100)

National Incident Management System (NIMS) (IS-700)

The Essential of OSHA Compliance (10-hour OSHA)

Certificate of Achievement, Safety Audits and Inspections

Certificate of Achievement, Incident Investigation and Analysis

Certificate of Achievement, A Practical Approach to Ergonomics

Certificate of Achievement, Ministerial Internship Program

Ordained Minister, Church of God (Cleveland, TN)

Licensed Minister, Assemblies of God (Springfield, MO)

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