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Engineering Maintenance

Location:
Athens, TX
Posted:
April 29, 2020

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Resume:

Robert W. Hooper

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

Kingwood, TX *7339

adc0kd@r.postjobfree.com C: 713-***-****

SUMMARY

Over 25 years successful experience in the development and implementation of corporate operational excellence, maintenance, integrity, turnaround and reliability programs within the oil and gas, consumer products, and specialty chemicals industries. Significant bottom-line success in safety, compliance, cost reductions and manufacturing capability improvements. Adept at strategic program management, budget development, change management, leadership development and coaching and staff organization/development. Specific expertise includes:

Global SAP PM/MM/PS Implementation

Lean Manufacturing

Kaizen

Six Sigma (Greenbelt)

RCM

RCFA

Turnaround and Outage Management

Mechanical Integrity program design

Organizational Change Management

Capital Project Management

Business Process Development

Training Program Development and Delivery

PROFESSIONAL EXPERIENCE

GENERAL ELECTRIC DIGITAL, Houston, TX 2019 – Present

Senior Subject Matter Expert

Senior subject matter expert for the implementation of GE’s APM system (formerly Meridium) in the oil & gas and chemical businesses. This includes RCM, RCFA, Asset criticality (ACA), Mechanical Integrity, strategy development, business process development, KPI’s dashboards and metrics. Also responsible for change management and training development and delivery.

AKZO NOBEL/NOURYON, Houston, TX 2018 – 2019

Senior Manager, Reliability Services

Leading the global maintenance, reliability engineering, capital project engineering, mechanical integrity, outage planning and ongoing operations of the companies chemical manufacturing facilities in the US and Europe.

Leading the maintenance, reliability engineering, capital project engineering, mechanical integrity, outage planning and ongoing operations of the companies chemical manufacturing facility. Responsible for staffing, maintenance and capital budgeting, organizational design and development and change management.

SYNGENTA CORPORATION/GB BIOSCIENCES, Houston, TX 2014 – 2018 (Company Sold)

Senior Manager, Maintenance and Reliability Engineering Operations

Leading a staff of over 300 engineers and technicians engaged in maintenance, reliability engineering, capital project engineering, mechanical integrity, outage planning and ongoing operations of the companies chemical manufacturing facility. Responsible for staffing, maintenance and capital budgeting, organizational design and development and change management. Assisting with the strategic plan development for the redeployment of SAP ECC 6.0 globally. Specific accomplishments include:

Reduce recordable injury rate by 50% by implementing an observation program and data analysis of near misses.

Reduced PSM incidents by 25% by implementing a formal system of operations checklists.

Rebuilt the mechanical integrity program which has yielded a more accurate inspection and mitigation program which has reduced the cost of reactive replacements by 30% and contributed to reducing overall risk of PSM incidents.

Designed and implemented an disciplined outage planning and execution program that yielded on time and on budget outages.

Developed the 5-year, (22 million dollar a year) capital plan that allowed preplanning of capital projects further reducing the need for expensive reactive replacement.

Reduced rotating equipment failures by over 50% by implementing an effective preventive maintenance program and a system of Operations equipment ownership and daily inspections.

Reduced storeroom inventory value by 15% by implementing an effective obsolescence program.

Developed effective maintenance, operations and capital execution business processes which reduced the cost of reactive maintenance and capital project execution time and costs.

Developed the outage scope and budget (@10 million) for the site operating units which reduce outage time and improved uptime.

Developed and implemented the SIS program which reduced the PSM incident rate and the costs associated with instrument failure during operation.

Implemented a leadership training program that focused on the development of future leaders while honing the leadership skill of existing leaders. This reduced turnover below 5%.

Established the Reliability Engineering team which engaged in RCAs and RCM analysis. This resulted in implemented recommendations which reduced reactive maintenance costs on selected systems by over 80%.

HESS CORPORATION, Houston, TX 2009 – 2013

Global Production Excellence Advisor

Team member for global program design and implementation of Hess’ production excellence program. Program includes the concepts of lean manufacturing, reliability engineering and six sigma. Responsible for the implementation and re-implementation of SAP ECC 6 worldwide.

Leading the team developing and implementing corporate and asset performance standards for integrity critical equipment for all assets including wells and gas processing equipment.

Developed the outage scope and budget for gas plant and offshore production platforms which reduce outage time and improved uptime.

Leading the preventive maintenance optimization for all global assets

Designed and led the Breakdown Elimination Program which includes leading the training and facilitation of Root Cause Failure Analysis (RCFA) for all assets including well, topside equipment and gas processing equipment.

Senior advisor to the KPI and dashboard team on maintenance and reliability.

Senior advisor for the Global implementation of SAP-PM

oLed the PM blueprinting and project plan development for the Global reimplementation of SAP PM to support maintenance and integrity data collection and analysis

oResponsible for the development of the global master data standards and the implementation of the master data management team.

Charter member of the Corporate SAP governance board

Led the initial implementation of SAP ECC 6.0 in Hess assets in the Permian Basin and Offshore Gulf of Mexico

Senior advisor for the global implementation of Lean Manufacturing initiatives.

HEXION SPECIALTY CHEMICAL, Houston, TX 2008 – 2009 (Company Dissolved)

Global Maintenance Excellence Manager

Managed a staff of 8 responsible for maintenance and reliability improvements for 29 chemical plants worldwide. Designed and implemented global maintenance and reliability objectives, goals, strategies, and tactics.

Managed the creation and implementation of a corporate level breakdown elimination program that used tools such as Root Cause Failure Analysis (RCFA) and delivered an immediate cost avoidance of over $7 million (US dollars) in one plant in Europe in 2009.

Identified and helped implement $6 million in cost savings through the use of Reliability Centered Maintenance (RCM) and Preventative Maintenance (PM) Optimization techniques in 2008.

Established and managed the global steering team in July 2008 that functioned as a strategic and tactical implementation body for program initiatives in 29 facilities worldwide.

Created a process to measure success through common Key Performance Indicators (KPI’s) and metrics that was implemented in all facilities.

Led improvements and managed SAP Business Process Office (BPO) for plant maintenance that helped establish best practices for SAP configuration and training.

Established the model for outage scope and budget for the site operating units which reduce outage time and improved uptime.

INDEPENDENT CONTRACTOR, Houston, TX 2006 – 2007

Marathon Oil 2006 – 2007

Managed the team responsible for the implementation of SAP PM/MM for Marathon Oil West African LNG plant.

CLOROX PRODUCTS CORPORATION, Houston, TX 1997 – 2006

Senior Manufacturing Reliability Engineer

Managed the staff responsible for maintenance and reliability engineering for Clorox owned businesses including Kingsford Charcoal, Clorox Bleach, Hidden Valley Ranch, Brita, Armor All, Soft Scrub, PineSol, and Formula 409.

Achieved an increase in productivity and efficiency of over 8% through the introduction of lean manufacturing and Kaizen methodologies, as well as other process improvements such as; breakdown elimination training and root cause failure analysis.

Led the team responsible for the implementation of SAP’s maintenance, project systems, inventory/ warehouse management and investment management modules for 24 manufacturing sites. Program resulted in the first ever successful multi-plant go live for SAP.

Reduced maintenance labor costs by 25%, by implementing an effective maintenance and reliability program that included, effective planning, scheduling, operator based autonomous maintenance, PM development and analysis and maintenance business process development. This program began in 1998 and delivered results within 18 months.

Led the implementation of MAXIMO for all North American and Latin American sites.

Increased available capacity in the Kingsford business unit by 15% by achieving greater line and machine reliability during the period between 1999 and 2001 by identifying and eliminating waste.

Developed the outage scoping, planning and budgeting process for the site operating units which reduce outage time, cost and improved uptime.

Developed a consistent set of KPI’s, manufacturing metrics and an assessment program that resulted in a consistent evaluation of manufacturing capability in all business units. This resulted in a ranked ordering of plants for focused efforts.

Led the introduction, development and training of manufacturing concepts such as TPM, RCM, SIX SIGMA, RCFA and Strategic Asset Management that resulted in over $5 million in savings between 2003 and 2006.

Established and led the reliability engineering group that was instrumental in avoiding equipment failure and increasing reliability and availability.

Life Cycle Engineering, Inc. 1987 - 1994

Regional Manager, Houston, TX

Participated in the design and implementation of process safety management (OSHA 1910) or Texas Eastman

Led the TPQM and production reliability program implementation for two worldwide offshore drilling clients that resulted in a reduction of unplanned downtime, lost time accidents and capital replacement budget dollars.

Led the production reliability program development and implementation at BASF that led to a decrease in planned shut down time and a decrease in unplanned downtime

Led the development and implementation of the PM program for Diamond Offshore and Falcon Drilling.

Carried out project planning and management. Managed budgets and project teams.

Performed FMECA and RCM analysis for two nuclear plants. Taught RCFA for PEMEX.

Staff Engineer, Charleston, SC

Developed and delivered maintenance management training and seminars series for several U.S. and international clients.

Developed maintenance plans and tasks for U.S. Navy Nuclear Submarines

Coauthored the Plant Manufacturing Reliability Assessment Program based on the principals of TQM, TPM and RCM.

MILITARY EXPERIENCE

1980 - 1986 United State Navy – Nuclear Submarine Service and Special Operations

EDUCATION

BS, Electrical Engineering Technology, West Coast University, Los Angeles, CA

The Pennsylvania State University, College of Electrical Engineering, Media, PA

CERTIFICATIONS / TRAINING

Masters Courses in Business-to-Business Marketing, George Washington University

Center for Creative Leadership, Eckerd, College 2000

Six Sigma Greenbelt, 2008

Lean Manufacturing, 2008

SAP PM,MM,IM implementation certification, 2000

Manufacturing Capacity Planning, Trident Technical College

Manufacturing Requirement Planning, Trident Technical College

Just-in-Time, Trident Technical College

Statistical Process Control, Trident Technical College



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