Anthony J. Puglia
Summary: 30 years of cement manufacturing experience. 14 years focused in SAP R/3 functional, configuration and implementation of production process, project systems and plant maintenance at multiple sites in USA, Canada and Puerto Rico. Recently completed a migration from 4.5 B to ECC 6.0 working together with a team of professionals here in the states and in Europe. Recently gained SAP Project Systems and Plant Maintenance application associate certifications with ERP 6.0 in. Over the past 4 years have exceeded objectives and responsibilities in performance and professional excellence.
Essroc Italcementi Group work history October 1984 to Present:
2007 to Present - Corporate Maintenance Manager
Responsibilities: SAP Plant Maintenance, application support, system configuration, functional integration testing, functional specification development and application training.
Major responsibility is setting up SAP project systems to run the annual expense plant maintenance.
Participate and support project team in developing plant maintenance refurbishment business process, integration testing training and rollout.
Manage cost tracking using the following types of reporting: PS summarization, cost element, line item, structure and hierarchical. Other types of reporting include list reports, PMIS, LIS, evaluation structures, exception reports, report painter, report writer and queries to monitor spending which have proved to be an excellent cost control that produced a costs saving of $18MLN over the past four years
Recently completed training for 35 control room operators on how to use a custom program to report equipment downtime. The SAP transaction provides the reliability engineers with the required equipment malfunctions and OEE reports to analyze breakdowns and production losses.
Provide problem solving expertise in SAP project systems, plant maintenance, materials management MDM, inventory controlling and production planning.
Designated as the functional key user for PM and PS for testing all system enhancements and validating transports that go into the SAP production environment.
Communicate SAP corporate maintenance polices and procedures to all salary plant maintenance employees on business rules for using SAP plant maintenance.
Gathered requirements to develop and customize an interface to load project system detailed cost planning using Microsoft excel.
Developed and implemented together with a senior analyst a standard set of SAP maintenance security roles to run plant maintenance based on organization hierarchy. The security roles reduced the number of SAP users who could access maintenance transactions from 500+ to 62, giving us a level of cost control never experienced before.
Developed and implemented an equipment catalogue system using the items object, damage, cause, as well as equipment classification to assign specific catalog types to the equipment catalog profile to track the root cause of breakdowns in the malfunction notification. Also linked the notification type to a failure work order activity type for further cost information.
Developed and implemented along with senior analyst a preventive maintenance inspection work order system using time based and activity based maintenance plans with the assignment of multiple task list items that included measurement points assigned to task lists operations.
Developed and implemented a user status profile with user statuses and authorization assignment in the notification and work order work flow process.
Managed the SAP setup of the technical structure for a new $625M cement plant. Created the functional location hierarchy, installed equipment, subassemblies, BOMs and used document management to attached technical drawings.
Classified equipment as per the Groups’ requirements.
Trained users how to plan and schedule work order operations to develop a critical path using the Network diagram and Gantt chart functionality.
1999 to 2007 - IT Business Analyst supporting PP, QM, LIS, FI, HR, PS, and PM
My primary responsibility during this time was to insure the SAP solutions satisfied the Group’s kernel requirements and compatibility to insure synergy and integration for improvement that help attain short and long term goals while gathering requirements and understanding the business.
Responsible for resolving system issues and working with ABAP developers and using SAP OSS when necessary. Provide support to the SAP users in maintaining data integrity during the month as well as month end closing process.
2007 - Lead in the implementation of the Production Quality Data Management System which is a web based reporting system. Reconfigured the PP module in order to become compliant with the kernel. Created new materials, units of measure, standard value keys, formulas, resources, recipes, BOMs, etc., essentially all the master data to run PP. Documented the new process, provided training and education and support during go live for all cement plants.
2007- Implement maintenance cost planning using SAP Project Systems replacing external system for maintenance expense cost tracking. Restructed all SAP PS and PM Master Data for 10 cement plants.
2006 – Became part of the Groups International Manufacturing Team.
Reconfigured the network from header assigned to operation activity assignment to manage a new project WBS structure for a $625M new plant. Specific requirements for planning, capturing costs and enhancement to PS for tracking details about specialization of job types, real estate tracking and tax abatement retirements and CATS.
Enhanced PS cost reporting with new value categories and PS summarization reports to align the nature codes used by the Group.
Use SharePoint as the repository for the technical documents to link SAP documents to technical objects using document management for the new cement plant project.
Traveled to Italy several times to prepare for considerable changes on how maintenance expense and investment are managed using the Groups physical structure to replace the planning done outside of SAP in a legacy systems and replacing it with SAP detailed cost planning.
2005 - 2006 Worked with Senior Analyst to develop a production resource downtime reporting system tied to OEE which was implemented world wide throughout the Group.
2005 - 2004 developed the IT equipment book depreciation report using asset evaluation categories.
Consolidated the vendor payment program reducing the number of checks cut per year.
Developed the admixture business dispenser tracking report.
Devolved an employee absence tracking report.
Configured the 401K age weighted benefits, salary book, and workman’s compensation interfacing with Pro Business.
Serve as team member in procurement to pay project where I had the responsibility of setting up the bar code scanning of PO’s and work flow.
During my stint in Finance and HR I started analyzing budget availability control issues especially with remaining order plan that involved capital projects which opened up an opportunity to focus mainly on the project system module.
2003 - I was directly responsible for configuring the SAP PP-PI module for a new cement acquisition. I converted 3500+ legacy system recipes to SAP materials, units of measure, and alternate units of measure, standard values, resources and recipes with multiple production versions. I provide education and training to the end users as well as support during the go live process.
2002 - Optimized the processes of month-end production data entry. I analyzed the processes and developed along with a senior analyst an improved process order confirmation entry system that reduced the data entry time for entering data and potential errors. I significantly increased my configuration skills in the area of PP and MM. It was also a year for an upgrade from 3.1 to 4.5B. I was in charge of ensuring hot pack testing for my area and ensured that the existing functionality seamlessly followed through to the new release.
1999 - 2001 Mapped the daily and monthly Operational Reports as the source of SAP reporting for Inventory, Production and Sales using LIS structures.
1997 - 1999 Corporate Process Engineer
Primarily focused on performing heat balances on cement kilns, mill grinding circuit evaluations, and clinker coolers air balances. Provide supporting data for capital investment.
Audited 8 cement plants finish mill grinding and clinker cooler processes in a six week duration.
Conducted control room operator training using Holderbank’s kiln simulator and computer based training.
Team lead in the SAP 3.1 H implementation of the PP-PI module, converting cement plant materials, resources and recipes to run process orders to capture daily production confirmations. Conducted training and developed power users and collected their requirements and provided timely support.
1995 - 1997 Plant Process Engineer
Responsible for maintaining the data acquisitions system and overseeing daily maintenance on continuous gas emission monitors. Responsible for cordintining the annual certification on continuous gas emissions monitors.
Ensure that equipments were running at design capacity to meet production requirements.
Track opacity and emissions and report to state on a quarterly basis.
Part of the commissioned team for the kiln indirect firing system.
Responsible for daily production report.
Conduct clinker cooler air balances to optimize airflow to a minimum while maintaining the lowest clinker discharge temperatures.
Responsible for capital projects that included new kiln seals, air shock cleaning system, replacement of primary process ductwork and data acquisitions system for tracking air emissions.
Identify false air across primay process duct work which led to a capital project to replace duct work from kiln ID fan thought raw mill and main precipitor. Realizes a 35 percent energy saving on main ID fan power. Optimized gas cooling water spray systems.
1991 - 1995 Safety / Utilities/Production Supervisor
Certified by the Mine Safety and Health Administration [MSHA] as a trainer to manage site specific safety training for all employees.
Responsible for accompanying MSHA during site inspections and coordinating manpower to address violations.
Developed a safety council involving both management and hourly employees which included a group of 10 individuals who became certified personnel trainers and performed area safety inspections.
Received training and certification in accident investigation.
Manage land leases, facilities and grounds maintenance.
Replaced dated plant telephone system and combined into one T1 line reducing annual communications expenses.
Organized and coordinated plant’s timber harvest.
Responsible for maintaining service contacts for fire suppression systems, elevators and pressure vessels.
1984 - 1991 Production Shift Supervisors
Supervised a team of 11 individuals to meet the plants objectives of safety, environmental, quality and production. Accomplish shift assignments in a timely manner. Analyze problems and find solutions to meet the production demands on a shift schedule. Demonstrate the ability to see projects through with a good working relationship with subordinates. Responsible for plant safety inspection during shift.
General Electric Wilmington NC
1983 - 1984 Chemist Internship
Trained to operate electron scanning microscope. Perform bench chemistry on product stream.
United Parcel Wilmington NC
1983 - 1984 Shipping Clerk
Ideal Cement Company Castle Hayne NC
1981 - 1982 Production Supervisors
Supervised a team of individuals to meet the plants objectives of safety, environmental, quality and production. Responsible for plant safety inspection during shift.
RCA Service Company Atlantic Undersea and Evaluation Center, Andros Island Bahamas
1980-1981 Base Chemists
Responsible for potable water production and distribution.
Recreation specialist 1978 - 1980
Westsail Corporation Wrightsville Beach NC
1975 -1977 Boat builder
Bachelors Degree, Indiana University (1991)
Earned 38 credits Industrial Chemistry, University of North Carolina (1984)
Associate Degree Marine Science, Cape Fear Technical Institute (1975)
Associate Degree Liberal Arts, Farleigh Dickenson (1973)
SAP certified in Project Management and Plant Maintenance ERP 6.0 (2010 and 2011)
Acquired certificates of training in SAP subject matters (1999-2011): PP, PP-PI, PM, PS, FI, CO, HR, LIS, Report Writer/Report Painter, Classification, Inventory Management, and Work Flow
ECC 6.0 R/3 (4.7, 4.6 HR, 4.5, 3.1H)
MS Office, MS Project, MS Visio, ASAP Methodology
PP//PM/PS, MM /Procurement, Inventory, FI/CO, Security (SU53)/ QM Minor
LIS, Query, SE16N, Report Painter/Report Writer, SM30 table maintenance, excel lookup functions and pivot tables