DOUG KOEPPEN

** ***** *****, ******, ** *****

Cell: 803-***-****

adrmss@r.postjobfree.com

CHEMICAL ENGINEER with 30 years experience in industrial manufacturing including project management, asset reliability, polymer processing, production of granulated and liquid fertilizer, water treatment, and textiles. Focused on improving operating performance by replacing or protecting capital assets, increasing profitability, and ensuring regulatory compliance. Able to create a team-based environment where employees work together to challenge and improve systems.

BUSINESS EXPERIENCE

Shakespeare, Columbia SC 2019 - 2022

PROJECT / PROCESS ENGINEER – Engineered Nylons

Developed and managed improvement projects and troubleshot process issues in a batch polymer plant that makes many different kinds of nylon.

Chemical tank project ($960K) – Scoped project to install larger chemical storage tank and re-use old tank for lower volume material. Authored request to gain approval for capital project. Managed project with multiple contractors.

Dryer repair/replacement project ($1.3M) – Investigated failure of inside shell on 55+ year old dryer. Managed repair project to brace the inside shell against further movement. Scoped project to replace the dryer.

Acid Handling project ($1.2 M) – Identified dust explosion hazard with our materials. Scoped multiple options for conveying powdered material.

Hot oil boiler replacement project ($650K) – Developed project to replace obsolete hot oil boiler and submitted capital project.

Improved control of viscosity after a process shift. Led a team through investigation process to determine root causes and correct process shift.

Investigated chemical spills. Directed team through investigation of two separate chemical spills. Identified root causes and put action items in place to prevent recurrence.

INVISTA, Camden, SC 2005 - 2019

Held four positions in company that manufactures nylon 6,6 polymer and yarn for the carpet industry.

ASSET AVAILABILITY LEADER 2016 – 2019

Tracked production unavailability and its causes. Focused efforts of Reliability group on highest value opportunities. Addressed gaps with cause map investigations and capital projects. Identified scope for overhauls and outages.

Drove design of new casting machine water header so that installation could be done without downtime to the process. This project addressed a major potential business interrupter.

Cut evaporator overhauls down from standard of 15 days to 9 or 10 days.

Improved area availability from 2016 – 82.9% (without monorail capital project installation – 6.0%) to 87.8% 2019 YTD July.

Step change in Casting Machine propulsion system problems by overhauling CM propulsion systems and replacing the floor rail.

PROJECT MANAGER 2013 – 2016

Managed multiple projects from concept and scope development through full funding and implementation. Coordinated people from many backgrounds to move the projects forward and identify and resolve obstacles to success. Managed cost, spending, and schedule. Several example projects listed below.

Recycled Nylon Grinding Project – ($2 million) Restored abandoned warehouse and installed new grinding, conveying and boxing equipment in order to recycle by-product material on-site.

Air Compressor Replacement – ($137 K) Instead of replacing air compressor in kind, scoped a more reliable system. Increased operating air pressure to maintain consistent supply and reduce operating hours on compressor.

Cedar Project – ($38 million) Operations Lead (Team Member)

oDeveloped commissioning strategy and plan. Trained and coached 17 commissioning leaders to develop and execute commissioning plans. Scheduled commissioning activity around construction.

oTracked progress on over 1400 action items and provided accountability for contractors and staff. Routinely communicated action item information to achieve completion.

POLYMER SPECIALIST FOR PROJECTS 2010 - 2013

Operations leader for multiple projects critical to the sustainability and profitability of the site. Scoped project details to ensure success. Managed project changes to happen safely and efficiently.

Batch Polymer DCS replacement project – ($16 million)

oPlanned cutover schedule for project implementation to balance project needs and operations requirements. Assembled team to create detailed written plan for each major cutover.

oEstablished training and documentation to ensure operators could run the new system before it was put on-line. Rewrote operating procedures and trained Adipic Operators.

HMD Tank Internal Inspection

Identified environmental risk and initiated project to address it. Coordinated detailed plans to isolate, enter and repair tank without safety or environmental incidents.

POLYMER SPECIALIST 2005 - 2010

Directed daily production for Batch Polymer area. Coordinated downtime for maintenance and projects. Supervised up to 14 operators controlling the batch process and unloading hazardous raw materials.

Identified need for improved safety controls around extrusion valve. Led FMEA analysis and participated in LOPA analysis to define changes. Helped implement installation of new safety interlocks.

Led culture change in area around environmental compliance. Created several training tools to communicate requirements to operators including “What to do if there is a spill” and “Training on air contaminants.” Coached team in the overhaul of plant spill reporting procedure.

Coordinated final design, details, installation, and training for new casting machines in 2006-2007.

PCS Phosphate, Aurora, NC 1994 - 2005

Held four positions in company that manufactures and sells bulk fertilizers around the world.

PRODUCTION ENGINEER – Fertilizer 2004 - 2005

Assured quality control and production of granulated fertilizer in three industrial plants. Redesigned granulated fertilizer plant to optimize production and control. Authored the justification to gain approval for $5 million project. Created conceptual flow and control diagrams. Drafted control description and screens for conversion to Distributed Control System (DCS).

PRODUCTION ENGINEER - Sulfuric Acid Department - Water Treatment 1998 - 2004

Managed company’s water treatment processes to ensure protection of capital equipment and uninterrupted production. Provided technical supervision for 8 water treatment operators and managed contractors for hydro blasting, cleaning, vacuuming and cooling tower repacking. Supervised multiple chemical suppliers including GE Betz and Nalco. Coordinated seamless transition to a new water supply system that provided 5-10,000 gpm of process water critical to the operation of 17 industrial chemical plants.

PRODUCTION ENGINEER - Superphosphoric Acid (SPA) - Tank Farm 1994 - 1998

Technically supervised 12 SPA operators running evaporators, filter presses and a liquid fertilizer plant and 20 operators running the acid storage tank farm including ammonia unloading and storage systems and sulfur unloading facility.

ENGINEER - Technical Services 1994

Investigated potential process improvements through bench scale, pilot plant and in-plant tests. Coordinated air-oxidation plant test.

Milliken Gayley Plant, Marietta, SC 1992 - 1994

PRODUCTION MANAGER

Managed 13 associates on shift in finishing department in a plant that produced automotive upholstery and Spandex fabrics.

EDUCATION

Bachelor of Science Degree - Chemical Engineering 1991

University of Virginia - Charlottesville, VA

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