Melanie Kozak

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

Bean Station TN *7708

865-***-**** (C)

Professional Experience

Value Added Solution March 2021-Nov 2022

Various customer locations

Oakridge National Laboratory, ETTP, Y12, TWPC, EMWLF, etc…

Obtained Q clearance while acting as the Subject Matter Expert for Welding, Codes Compliance, Metallurgy and Mechanical/Structural Engineering where I served as the primary point of contact under UCOR to the appropriate DOE program office.

Authored and implemented the infrastructure, procedures, processes and department personnel training to perform code designs the implementation of the Subject Matter Areas throughout all functions for project engineers and project managers.

Supported program definition through the selection of applicable standards and requirements throughout the UCOR departments and project execution teams.

Provided support, management of standards and the flow down of requirements for self-performed work in the weld shop as well as on the project sites during installation activities.

Performance Document Process and for subcontracted work and system procurements.

Performed management assessment of a variety of processes to correct issues and provide continuous improvements within the departments, maintenance and work planning, training, work process, during design and construction phases.

Authored multiple white papers, issued lessons learned and notes of wisdom to improve future project execution.

The UCOR interpretative authority for the Subject Matter Areas that were assigned. heir purview. reviewed training courses periodically provided suggested changes to courses where beneficial.

Reviewed trend data and other feedback associated with the Subject Matter Areas and provided feedback to the project, functional, and senior management on the effectiveness of the Subject Matter Areas assigned.

Trained and certified all weld personnel such as pipefitters and Ironworkers under the UCOR code welding program. Worked with the local unions to recognize efforts through reciprocity for both UCOR programs as well as their own.

Code Design & Engineering 2013 – March 2021

Various customer locations

Eng. Consultant for Various clients in Automotive Ind.: Project Launches/Technical Expert/Welding/Quality

●Management and supervision of all 3 shifts of the following engineering/manufacturing technical services departments: Cut N Etch, Destructive/Nondestructive weld testing, CMM Lab, gage/calibration Lab, incoming inspection receiving, dock check-random inspection of manufactured products prior to shipment, performance testing of all components at subassembly and final assembly levels, tensile pulls/bend tests, ft/lbs push out force test on all threaded components, recliner position performance testing, etc…

●Perform root cause analysis of noncompliant components due to product nonconformance, weld failures, etc…

●Managed CIP teams to improve efficiency started with robotic weld cells, fixtures, tooling & dies, tube benders, etc…

●Author procedures to ensure all productions personnel perform manufacturing functions properly and obtain repeatability.

●Providing welding training and certification of production personnel as required by Ford and GM requirements.

●As a CWE I Proctored/certified all welding personnel globally to comply with AWS D1.1 standard.

●Generated all WPS, PQR’s, WPQ’s in accordance with AWS D1.1

●Project manager for the existing programs with all major automotive clients such as GM, Ford, Hyundai, Toyota, Chrysler, etc…

●Launched all new programs from design concept thru transitioning into the plants. This included robotic equipment specification, procurement, external fabrication, prototype component runoff at equipment suppliers facilities. Responsible for overseeing equipment transfer, plant installation/startup and commissioning. Transitioning into full production lines, including all time studies, PPAP’s, authoring DFEMA, PFMEA, PCP’s.

●Oversee all equipment, tooling, dies construction necessary for testing and validation of new products to support manufacturing efforts.

●Developed, validated and Implemented new technology needed to reduce scrap globally across 230 plant corporation thru Phased array NDT weld testing vs. destructive testing which resulted in $150mm in savings globally.

●Researched validated and implemented method for positive material identification (Mass Spectrograph) to minimize wear on tooling due to noncompliance chemical composition of non-domestic steels. This extending tooling life and reducing tooling maintenance resulting in a significant savings

Consultant for Pharmaceutical Clients: Technical Expert auditing Eng, MFG, Welding, Validation, Quality

●Provided technical support at a corporate level for assessments of all existing methods of sales, manufacturing, validation and performance testing, cleaning / passivation, electropolishing, etc… Ensured compliance with FDA requirements as they relate to Pharmaceutical equipment’s used to produce products in Food, Beverage, Dairy, Cosmetics, Pharmaceutical, etc… Industries

●Trained new applications engineering personnel to properly evaluate customer specification and provide terms and conditions as well as exceptions and clarifications to improve product sales and overall profitability.

●Evaluated Engineering’s procedures and protocol as well as their knowledge and ability to comply with SEP (sound engineering practice). Implemented new procedures to ensure compliance. Trained all department personnel to new procedures.

●Provided the same type of evaluation of the existing manufacturing processes to cGMP. Implemented all necessary procedures, trained manufacturing personnel and oversaw changes to become compliant.

●Audited existing methods being used to electropolish high purity process contact surfaces of fabricated equipment, piping, internal components, etc… Implemented all necessary changes to improve polishing methods so a minimum of 15ra finish could be achieved. Trained quality personnel on proper methods of inspecting surface finishes.

●Created procedures and trained personnel to perform detergent cleaning (alka-jet) and passivation to comply with their customers’ specifications.

●Oversaw the addition of a plant expansion to produce a new product line which for WFI stills and clean steam generators.

Lonza Corporation 2012-2013

Charleston, TN

Contract: Project/QA/Construction/Welding/ASME Code Engineer

Optimization of the Spin Flash Dryer system for the Chlora-alkali unit. This task has approximately 22 extensive subtasks.

As the Project Mechanical Engineer for the CAPEX efforts. I am responsible for the system engineering for the mechanical side as well as overseeing all other design disciplines (i.e.; I&C, Electrical, Structural Engineering, Designers as it relates to my scope of work). This entails meeting with the plant management personnel to determine what equipment is needed to expand as well as optimize the existing plant production rates to obtain the needed capacity increase due to market demands. My PE activities entail generating technical design documents for various equipment’s such as pneumatic conveying equipment, chutes, hoppers, pressure vessels (section VIII Div I & II as applicable), Instrument/Valve schedules, Turn Over Packages. Authoring technical baseline equipment scopes; equipment specification sheets; process flow diagrams, I&C controls logic, etc… Preparing QA/QC inspection test plans (ITP’s) as related to fabrication hold points, NDE, Hydro testing, operational performance testing, etc… Oversee construction activities as it relates to CAPEX scope. Meet with General Contractor as needed and provide any technical support during construction phase. Oversee HAZOP meetings and document all meeting minutes and provide thorough organized and accessible database for reference data extracted during the meetings.

As the Project Manager for the CAPEX efforts. I am responsible for the budget allotted for 2012 CAPEX activities as well as schedule. This entails generating technical bid documents for all equipment as necessary; perform site inspections for approval of new equipment suppliers as needed. Interface with existing suppliers to ensure we obtain the needed equipment and comply with schedule and budget targets. Schedule and host weekly CAPEX meetings to discuss activities. Issuing all bid documents, drawings, specs, etc… to purchasing as needed to comply with schedule/budget. Monthly meetings with plant management to discuss all CAPEX activates as it relates to Schedule and Budget.

Upgrading the plant #3 Boiler due to higher steam output needed to meet future market demands.

Inspect boiler and make recommendations of necessary repairs/alterations to existing 1980 Nebraska Boiler Unit. Author spec that conveyed proposed recommend boiler repair/alteration details which include scope, hold point inspections both by AI and Owner. Issued for bid and met with potential repair firms. Upon selecting repair firm, hosted kickoff meeting to convey all planned activities. Completed job safety assessment due to confined space entry requirements. Oversaw boiler repairs activities both as the project engineer and level II Senior CWI, witnessing hold points.

Bayer Corporation 2011-2012

Baytown, TX

Contract: Project/QA/Construction/Welding/ASME Code Engineer

Project Engineer responsible for overseeing all equipment design review, fabrication, installation, construction and star-up/commissioning of all equipment need to expand the MDI Trane Project located at the Baytown TX Bayer site. Much of the equipment is used in a lethal service condition for the production of Methylene diphenyl isocyanate (MDI) which is a chemical used primarily to manufacture polyurethane foam. In conjunction with these activities I am also responsible for fitness for service (FFS1 / API 579) evaluations of existing plant equipment. This entails entering the unit area and providing a full examination via NDE and providing a written report of the existing equipment condition. Generating calculations based on actual thickness readings from my reports and establishing the MAWP. If rerating is required I generate a repair plan and scope with all AI/Customer hold points and select the appropriate repair firm. I am responsible for overseeing all repair efforts and signing off on final As Build documentation.

SunCoke Energy (Division of Sunoco) 2008-2011

Knoxville, TN

Project/QA/Piping/Welding/ASME Code Engineer

Project Engineer responsible for overseeing the design review, fabrication, installation, construction and star-up/commissioning of metallurgical coke production facilities with full power generating capabilities. These facilities consist of multiple waste Heat Recovery Steam Generator (HRSG’s), condensing turbine (STG) with cooling tower and auxiliary dump condenser which allows the HRSG’s to continue operation without the steam turbine generator. Each HRSG will receive the exhaust gas from a bank of 20 Coke Ovens and in turn will use the hot exhaust gas to generate high pressure super heated steam which flows through a common header supply to the steam turbine. Flue Gasses are scrubbed using flue gas desulfurization system which is a semi dry process that uses lime and water to create an exothermic reaction as the gasses are introduced.

Responsibilities consist of : Specification and scope authorization for bid proposals, design of infrastructure, analysis, equipment calculations, design drawing reviews, oversee fabrication and construction. Oversee all construction efforts performed by contractors from an Engineering, Construction and QA/QC perspective. Oversee start up and commissioning efforts and implement turn over to operations once construction is complete. Provide extended technical support to operations during transition phase.

Facilitate operations during maintenance outages. Spec. replacement equipment and author repair procedures where needed. Write weld procedures (WPS’s & PQR’s), test welders and issue WPQ’s for plant maintenance applications.

Aqua-Chem Water Technologies Division 2001-2008

Knoxville, TN

Project Engineer/ASME Code Engineer

Project Engineer responsible for design and manufacture of various types of water purification equipment.

Perform ASME Code calculations per Sections I & VIII for Tube & Shell Heat Exchangers (TEMA &UHX), Boiler Channels & Tube Bundles, Economizers, Condenser Vessels & other miscellaneous vessels.

Perform calculations of Dynamic Loads per UG-22 requirements.

Responsible for design, manufacturing and validation/operational testing of WFI Vapor Compression Stills, Pure Steam Generators, Waste Heat Evaporators, TWPS (Tactical Water Purification System used for the Military) Reverse Osmosis Water Purification Systems & Vapor Compression Bottle Water Units.Ensure compliance of all applicable codes during fabrication such as: ASME Sections; BPE (Biopharmaceutical Pressure Equipment), VIII (Unfired Pressure Vessels), ANSI B31.1 & B31.3 Piping Codes. Review Designs with the Authorized Inspector (AI) to verify ASME Code Compliance, Witness

Hydrostatic Inspections with the AI and endorse required documentation for registration with

The National Board. When required on behalf of Quality I would meet with Authorized Inspector, witness hydrostatic testing of code pressure vessels and complete required data sheet for National Board Registration.

Responsible for compliance with all international codes such as NR-13 (Brazilian), JIS (Japanese), MOM (Ministry of Manpower), PED (Pressure Equipment Directive), SQL (Chinese), etc… I gave guidance and technical support to all departments such as QA, Purchasing, Manufacturing & Receiving any requirements necessary to meet the appropriate codes.

Review Customer Specifications and provide technical exceptions and clarifications for quotes, Design & Engineer new products and implement cost reductions for existing designs as needed. Provide Technical Support to Sales, Quality, Manufacturing and Purchasing when required.

I have done extensive research and development of new types of Clean Steam Generators in efforts to become more competitive in the industry.

Upon completion of projects I was responsible for generating and publishing Project reports validating Engineering/Manufacturing hours, loss or gain in profit margin, reconciliation of overbuys or excess material, etc…

Final task of authoring Technical Specifications for operation and maintenance of equipment designed and overseeing completion of Operation Maintenance Manuals.

Precision Boilers. LLC 1996-2001

Morristown, TN

Pressure Vessel Engineer/ASME Code

Perform ASME Code calculations per Sections I, IV & VIII for High Pressure Boilers, Hot Water

Heaters, Lined Storage Tanks, Deaerators, Heat Exchangers etc…

Perform calculations of Dynamic Loads such as Seismic analysis, Wind Loadings, Nozzle

Loadings {WRC107-297}, Hydrostatic Loads, Center of Gravity

Oversee the completion of Data Reports, Manufacturing Drawings, and issuance of shop travelers.

Ensure compliance of all applicable codes during fabrication such as: ASME Sections I, IV & VII

ISO 9001 compliance, Requirements meeting our “China License”.

Review and Approve all Nondestructive Examinations required, Issuance of Radiography reports

Heat treatment charts.

Review Designs with the Authorized Inspector (AI) to verify ASME Code Compliance, Witness

Hydrostatic Inspections with the AI and endorse required documentation for registration with

The National Board.

Review Customer Specifications, Design & Engineer New Quotes and Provide Technical Support

To Sales & Marketing.

Kaydon Corporation 1991-1996

Greenville, TN

Product Manufacturing Engineer

Design of new products, Update existing product lines, Design of Tooling and Fixturing,

Provided Cost Reduction Analysis.

The vast majority of products were customer driven. This would entail a thorough review of

customer specifications to ensure complete compliance of all electrical components, piping

standards, manufacturing techniques and testing procedures and any ASME Code compliance

required. Findings would then be discussed with the Quality Control Manager and the Production

Department for resolution. Any customer specification, which required a more labor intensive

process would require a cost impact of labor and materials as well as engineering time and resource.

This would then be directed back to sales for customer approval. Once the details were worked out

sales/quote drawings would be generated. These drawings usually included Logic Diagrams as

well as assembly views.

From these drawings I would create detailed sketches along with bills of material for the CAD

department to create detailed manufacturing drawings. After BOM generation I would perform

Code calculations. Then the BOM would be entered into the mainframe computer (Copics II/IBM

System). After checking all BOM’s, routings and drawings I would release the production

Package to manufacturing.

Other responsibilities included any applicable jig, weld fixture and/or tooling required to facilitate

production. Provided technical support to customers, field service, manufacturing, sales

purchasing, production control, quality control and accounting.

Ingersoll-Rand 1988-1991

Roanoke, VA

Tooling Designer

Designed tooling for parts used in the manufacture of pavement breakers, ECM crawlers,

Hydraulic hoists and wenches, hand held power tools. Some of the components designed were

milling fixtures, grind arbors, rechucks, chuck jaws, special cutters, end mills, reamers, and hobs

broaches, back face bars, knurling tools, holders, drivers and various gauges used in quality

control.

Acadia Polymers 1984-1988

Roanoke, VA

Products/Tooling Engineer

Parts designs, tool designing, equipment designs for the automotive, heavy equipment and business machine industries. Worked with lab to develop shrinkage on various polymer

compounds, which were then incorporated into the mold design. Determined the

maximum number of cavities possible. Coordinated work with machine shops. Trained

engineering personnel on CAD system design. Responsible for daily systems backup and

monthly archive, programming commands and writing shell scripts (Fortran, C and GMS

languages). I was also responsible for systems maintenance and management. Kept daily

drawing logs, complete system documentation and dealt direct with sales and marketing.

Grumman Emergency Products 1982-1984

Roanoke, VA

New Product Engineer

Worked under contract for Norrell Temporary Services. Designed Metropolitan Body which

involved shortening the standard truck frames from a 186” wheelbase. Modified drive train and

chassis to accommodate new dimensions. Designed all compartments, backup water storage

tank including manifold and all water control valves, piping assemblies etc… Dealt directly

with the Marketing department discussing designs and addressing customer’s needs. Was

also responsible for complete drawing log and full documentation of designs 1986-1989

PROFESSIONAL REFERENCES :

Robert Parnell, Houston, TX Director of Operations at TPC Group 713-***-****

Keith Kaufman Chicago, IL General Manager Cokenergy 615-***-****

Stephen Heater, Knoxville, TN Mechanical Engineer UT Battelle 865-***-****

Tracy Gamble, Knoxville, TN Project Manager Helix Systems 865-***-****

Danny Guedry, Knoxville, TN Project Engineer Bechtel Inc 865-***-****

Dabney Lancaster

Covington, Va. 1984

Graduated with a Technical Degree in Mechanical Design Technology

Virginia Polytechnic Institute

Blacksburg, Va. 1990

Graduated with a Bachelors Degree in Mechanical Engineering BSME

Unysis Training Center 1989

Boulder, CO

Unysis/Cadam (2nd, 3rd & System Management)

Hartford Pressure Vessel Design Seminar 1992

Chattanooga, TN

ASME Code Vessel Construction

Pellissippi State College 1994

Knoxville, TN

AutoCad Design I & II

Performance Training Associates 1995

Knoxville, TN

Electrical Ladder Drawings Analysis

CUI & Inspection Pressure Vessel Design Seminar 1999

Charlotte, NC

ASME Code Vessel Construction

Hartford Pressure Vessel Design Seminar 1999

Chattanooga, TN

ASME Code Vessel Construction

Pellissippi State College 2003

Knoxville, TN

API 1104, AWS D1.1 & AWS CWE Certification

QCI-96 Certification Number 03020231

Emerson Process Management 2003-04

Knoxville, TN

2130 Machinery Vibrations Analysis Level Catagory I thru IV

Advanced Vibrations Research and Analysis

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