PROFESSIONAL RESUME

Robert D. Kitchen, CPE

Principal Reliability Engineer

Certified Plant Engineer with 0ver 40 years of Engineering and Reliability experience focused on equipment reliability and continuous process improvement as an RCM leader and change management practitioner.

Experience working domestically and abroad within a broad spectrum of industries including Biopharma, Mining, Marine, Power Generation, Beverage Manufacturing and Municipal Water Treatment. Professional level experience in multi-cultural and overseas environments: (China, Philippines, India, Spain, Malawi, Brazil, Canada, and Mexico).

Skilled Enterprise Asset Management (EAM) & Reliability adviser with successful software implementation projects at leading-edge companies such as: GE, Pfizer, Honeywell, NASA, Safeway, Con Agra, Coca-Cola, and Westinghouse.

Expert equipment Reliability Engineer with hands-on application of dynamic balancing, precision alignment, vibration analysis, ultrasonic testing, infrared thermography, and oil analysis technologies.

Team leader, coach, mentor, and proven Project Manager with strong interpersonal skills.

PROFESSIONAL HISTORY

2005 – Present Principal Reliability Engineer, Founder, EXIM Reliability Group

2004 – 2005 Corporate TPM Manager, Safeway Supply

1999 – 2004 Director of Operations, MEC & DP Solutions Inc

1997 – 1999 Senior Project Manager, DP Solutions Inc

1993 – 1997 Chief Engineer, Danmor/Devcon Properties

1984 – 1993 Senior Engineering Technologist, Westinghouse Electric Corp.

1979 – 1984 Machinery Erector, IAM Local 692

1973 – 1979 Marine Machinist, IAM Local 297

1971 – 1973 Aircraft Machinist, USAF

SKILLS

Asset Management

Predictive Maintenance

Reliability Program Development

Criticality Analysis

Failure Modes Effect Analysis (FMEA)

Shutdown Planning & Scheduling

Preventive Maintenance Optimization

TPM Implementation

Reliability Training

Project Management

CMMS Implementation

Reliability Centered Maintenance

SOFTWARE APPLICATIONS

Maximo

MS Project

SAP-PM

INFOR

CalMan/Blue Mountain RAM

Imaint

Fusion

Ellipse

PMC2000

JD Edwards

Crystal Reports

LAI PMO Tool

EDUCATION/CERTIFICATIONS

Granton Institute of Technology, Professional Diploma, Mechanical Engineering Technology 1987 - 1991

Certifications:

Certified Plant Engineer (AFE) formally American Institute of Plant Engineers

Certified Millwright/Industrial Mechanic BC Ministry of Labor (Red Seal)

Journeyman Machinist International Assoc. of Machinists Joint Apprenticeship Council

Certified Excellence in Maintenance (EXIM) Advanced Trainer, The Coca-Cola Company

Training:

American Management Association Advanced Leadership course

Effective Maintenance Management course, University of Washington

Caterpillar 3500 Series Mechanical and Electrical diesel power generation

RCM2 Practitioner training, Aladon Network

Lean Maintenance & Reliability Workshop, Ivara Corp

Maintenance Planning & Scheduling, New Standards Institute

Preventive Maintenance Optimization, LAI Reliability Systems

Publications:

Technical white paper on Diagnostic Engineering published in the AFE (Association for Facilities Engineering) Journal (December 1999)

U.S. Government Security Clearance:

Department of Defense – Top Secret - Inactive

Department of Energy – Q - Inactive

PERSONAL INTERESTS

Boatbuilding

Sailing

German Shepherd Training

AMPLIFIED RESUME

CLIENT ENGAGEMENTS & PROFESSIONAL EXPERIENCE

Great Lakes Water Authority: Detroit MI, Principal Reliability Engineer

Facilitated a remote Design for Reliability workshop with the primary engineering firm Hazen & Sawyer used by (GLWA). The purpose of the workshop was to instill reliability into every aspect of the asset management process from conception throughout the lifecycle of the equipment. The team consisted of key members of the Design, Asset Management, Plant Engineering, Operations and Maintenance groups. The workshop emphasis was on mitigating or eliminating equipment failures by utilizing the latest in equipment monitoring technologies. Special focus was given to equipment Operating context, Maintenance strategy, Accessibility, Operability and Reliability prior to specifying the equipment.

Kite Pharmaceuticals: Santa Monica CA, Principal Reliability Engineer

Performed a remote Maintenance Task Analysis for Power Distribution, Emergency Power Generation, UPS, Fire Protection, CO & LN systems. Specified NFPA Inspection and testing requirements. Developed new job plans from FMEA data that incorporated regulatory requirements at correct frequencies.

Pfizer: McPherson KS, Principal Reliability Engineer

Worked with GRP Management and technical staff to develop maintenance strategies for critical Air Handling units, Autoclaves, Clean Steam Generators, Air Compressors and Cooling Towers. Performed Asset criticality analysis and reviewed with corporate SME’s. Performed Job task analysis of current maintenance program to determine effectiveness. Reviewed equipment failure mode database to ensure all failure modes were addressed. Edited EAMS system with updated task list and scheduled maintenance at designated intervals.

Bend Research/Capsugel/Lonza: Bend, OR. Principal Reliability Engineer

Contracted to institute a corporate wide Reliability Program to support new European product manufacturing equipment. Process mapped current Reliability practices to identify gaps in current system and develop new corporate Reliability policies. Developed a 5-year strategic plan to implement the Reliability Program across all corporate assets. Worked with pilot plant Subject Matter Experts to perform Asset Criticality Ranking for all pilot plant assets. Performed FMEA analysis of critical production assets. Developed asset class maintenance strategies based on analysis results. Identified Critical & MRO spares and developed stocking strategies. Standardized job plans across asset classes to include Job hazard analysis, Safety Requirements, Special tools, Craft Skill level, Plant Conditions, inspection Pass/Fail criteria and wrench time to complete each task. Identified reports needed to manage performance metrics. Consulted with EAM software manufacturer to make improvements to support the Corporate Reliability Program. Initiated Ultrasonic Lubrication, Vibration Analysis, Oil Analysis, IR Thermography and Operator “Look, Listen and Feel” routes for critical equipment. Reliability improvements enabled the business to be Recertified by Swedish MPA creating new business opportunities. Capsugel has been acquired by the Swedish firm Lonza.

Shire Bio Pharma: Andover, MA, Principal Reliability Engineer

Contracted to staff and develop a Planning & Scheduling group to support a new Maximo Implementation. Interviewed perspective candidates for Manager of Planning & Scheduling, MRO Planner and Project scheduler. Developed Engineering procedures for governance of the group. Developed a visual schedule compliance program reviewed at the daily GEMBA meeting. Delivered work order backlog management system that reduced backlog by 28% in 4 months. Established a Work Priority system with triggers that indicated work that was near its maximum response date. Planning & Scheduling team was working independently with established KPI’s 2 months before the Maximo program was scheduled for roll out.

Gilead Science: La Verne, CA, Principal Reliability Engineer,

Developed Reliability business processes at their new Greenfield facility in La Verne, Ca. Created master equipment lists and performed asset criticality analysis on newly installed equipment. Worked with management to develop maintenance strategies based on criticality ranking and instituted a condition-based maintenance program using world class technologies to monitor equipment health. Developed and delivered non-intrusive failure mode based Preventive Maintenance program that allows equipment inspections while equipment is running. Proposed a real-time condition monitoring program for critical assets that generates fault signals to Maximo to auto generate corrective maintenance work orders. Set up Gilead’s lifecycle costing program for the recently commissioned equipment to better manage and forecast future capital investment.

BBraun Medical: Santa Anna, CA, Principal Reliability Engineer

Applying RCM principals, evaluated newly installed prototype intravenous (IV) bag manufacturing machinery to establish a life cycle maintenance strategy. Developed operator-based maintenance procedures, Preventive Maintenance standard work instructions using graphic illustrations to provide step-by-step technical guidance. Instituted a condition-based maintenance program, using Infrared Thermography and Ultrasonic scanning technologies to insure reliability. Identified Critical Spare parts using criticality analysis and created data upload template to upload all spare parts data into SAP-PM. Created documentation to support the equipment Initial Qualification (IQ) process.

Algonquin Power & Utilities: Montreal, QB, Principal Reliability Engineer

Performed a corporate Reliability Assessment of all U.S. and Canadian Hydro, Solar and Wind turbine operations. Performed a Gap Analysis of current operations for each business unit compared with industry best practices. Delivered a comprehensive assessment report including Return on Investment (ROI) and outlining leverage points and opportunities to later be integrated into an actionable corporate Enterprise Asset Management (EAM) master plan.

DC Water Treatment Plant: Washington, DC, Asset Management Advisor

Provided task support services in support of Asset Management Pilot Project in Washington D.C. Reviewed current Maximo PM Program with SME’s and suggested improvements that would eliminate low-value work. Developed a condition-based maintenance program using RCM principals to minimize failures. Created asset class job plans that were craft specific with LOTO, Job Safety Analysis, Spare parts, Special tools, and skill qualifications. Pilot project involved 1200 stationary and rotating assets within the final filtration process. The purpose of the project was to identify new technologies that would monitor machine health and interface with the current SCADA program. The project eliminated 2900 hours of unproductive PM tasks and improved equipment reliability by eliminating many intrusive inspections.

Capstone Mining: Zacatecas, MX, Principal Reliability Engineer

Organized, coached, and developed a high functioning internal reliability team to improve production output and equipment reliability at the Capstone Copper Mine in Zacatecas, MX. Trained team on RCM and RCA techniques. Completed FMEA’s for all critical equipment to address maintenance & operational gaps. Instituted new maintenance and operational safe work procedures and job plans that improved availability of a critical hoist by 8%. Improved uptime of mobile drilling & hauling equipment by implementing better work planning, scheduling and work management practices.

Hanford Nuclear Facility: Hanford, WA, Principal Reliability Engineer

Completed a proprietary reliability assessment of the Hanford Nuclear Facility Water Treatment and Electrical Power Distribution system. Provided a detailed gap analysis report of 23 key areas and improvement opportunities. Prepared a detailed project plan submitted to Department of Energy for future budgeting and funding.

ENDO Pharmaceuticals: Huntsville, AL, Senior Reliability Engineer

Performed RCM analysis of critical fluid bed dryer equipment increasing availability from 68% to 76% in four months. Lead annual shutdown planning effort that successfully accomplished 100% of scheduled maintenance activities, completing critical upgrades and improvements that increased competitiveness within the industry.

Anglo America Mining: Tumbler Ridge, BC, Senior Reliability Engineer

Contracted by Anglo American Coal to improve equipment availability from 81% to 90%. Lead a cross functional RCFA team to quickly identify oversize coal as the root cause of poor plant performance. Implemented an operator-based maintenance (OBM) program that monitored coal size at key screening points. Utilized diagnostic technologies to identify the source of high vibration that caused a 15” critical support I beam to fail. Implemented a PdM program that identified many hidden defects that were scheduled and corrected before failure.

Price Waterhouse Coopers: Longview, WA, Asset Management Advisor

Engaged to develop and deliver reliability improvements at the Longview Fiber Mill. Deliverables include end-to-end business processes to improve overall asset performance at the Pulp & Fiber mills. Developed & Implemented Root Cause Failure Analysis (RCFA) Programs with triggers based on costs, availability, and bad actor analysis. Instituted asset type failure codes to support Reliability KPI’s. Performed RCM analysis to establish overall maintenance strategy for all critical assets. Worked with in house SME’s to optimize current Preventive Maintenance & Condition Monitoring Programs, formed new Lubrication routes and Operator Based Inspections as part of the Tango program implementation.

Pfizer Global Engineering: Senior Reliability Engineer

Delivered on-site support for corporate Global Reliability Program, performed over 17 on site Reliability Excellence Assessments, compiled reports and developed actionable project plans to attain expected results. Trained site personnel in reliability engineering techniques and FMEA processes. Performed Asset Criticality Analysis, PM Optimization and Bad Actor Analysis utilizing EAMS, CalMan, Fusion and SAP-PM program data to drive reliability improvements.

Twin Rivers Paper: Edmundston, NB Principal Reliability Engineer

Assessed Reliability and Maintenance programs, recommended improvements based on cross-industry best practices. The project included the following:

Asset Criticality Analysis

Root cause analysis

Failure Coding

Bad Actor Identification and remediation

Shutdown Planning

Coaching site personnel on Reliability Program methodologies

King County Water: Seattle, WA, Principal Reliability Engineer

Assessed the current reliability program, maintenance practices, and CMMS usage. Performed PM optimization that eliminated 3900 hrs. of low value PM work. Provided coaching and training to site personnel in industry best practices.

Wyeth Nutritional’s: Canlubang, PI, Principal Reliability Engineer

Improved reliability and plant performance at baby formula manufacturing plant in the Philippines. Specifically focused on improving reliability on bottleneck equipment, changing the plant culture from firefighting to proactive engagement, and implementing a reliability program to sustain the improvements over time.

Key elements of the program implemented:

Used reliability tools such as FMEA, root cause analysis, statistical analysis for trending of bottleneck equipment

Implemented a criticality analysis process

Instituted a PM optimization program for the site to eliminate non-value-added tasks and implement PdM technologies to improve reliability

Used one-point lesson plans to train operators and standardize operating procedures to improve equipment performance and reliability

Implemented a three-year Reliability Program strategy to define goals, identify key milestones and implement metrics to measure progress.

Implemented a “cascading objectives” methodology to align all plant personnel (from Managing Director to shop floor operators) with reliability goals and create accountability for achieving annual targets

Built a reliability program for the new site expansion project

Project results included: Increase of MTBF on critical packaging equipment, reduced critical equipment intrusive cleaning and turnaround time that improved production output by 20%. Developed several continuous improvement teams that executed reliability improvements, changing the plant culture from reactive to proactive.

Safeway: North America, Corporate TPM Manager

Developed and implemented corporate TPM program across 33 plants in North America. Trained TPM champions for Bakery, Dairy, Grocery and Beverage business units. Lead Kaizen events for blow mold machines, Pick & Place Robot, and pop casing machine. Focus was on developing cleaning, inspection, and maintenance activities to restore aging equipment to design functional condition. Kaizen events identified hidden defects such as a cracked magnetic head on a critical robot that was not found during normal maintenance. Restoration & Repairs were made to extend the useful life of the equipment, freeing CapX funds to be used for other high priority improvements.

Coca-Cola: Blantyre, Malawi, Senior Project Manager

Responsible for implementing a corporate Computerized Maintenance Management System in Malawi Africa. Worked with Coca-Cola in Atlanta as a subject matter expert to develop and implement the Excellence in Maintenance Program (EXIM) for the African bottlers. Developed simple maintenance procedures for unskilled production and maintenance workers. Trained plant personnel to follow EXIM principals during plant maintenance activities. Improved reliability measured by uptime improvement and OEE such that Coke was able to mothball the Muzuzu plant which was recently built to insure future production capacity.

Contact this candidate