Process Engineer Continuous Improvement

Resume

Wade Xu (Weijian Xu)

Email: ***********@*****.*** Cell Phone: +1-256-***-****

Professional Summary

Results-driven Process Engineer with 30 years of expertise in industrial fibers, fabrics, and home textiles. Strong background in process optimization, cost reduction, and new equipment installation. Proven success in Lean Six Sigma, process improvement, and operations management.

Bachelor's degree in Applied Chemistry from South China University of Technology.

Expertise in Solid State Polycondensation (SSP), synthetic fiber processing (PET, PA66) and industrial fabric production, and plastic processing (PE, PP, PVC).

In-depth knowledge (PET, PA66, PE, PP) of extrusion, quenching, drawing, winding, twisting, warping, weaving, dipping, tufting, coating.

Skilled in new product development, supplier optimization, and cost-saving initiatives.

Proficient in Lean Six Sigma (DMAIC, C&E, SPC, FMEA, VSM, SMED, Minitab) for continuous improvement.

Key Skills & Competencies

Strategic & Operational Management

Developed 5-year strategic plans and annual budgets using SWOT analysis, leading to 16% revenue growth at Esquel.

Expertise in new product development (NPD) and continuous improvement (CI).

Implementation of ISO 9001 and ISO 14001 quality and environmental management systems.

Experience in HSE procedures, including Zero Energy, Tagout & Lockout, Job Safety Analysis (JSA).

Process Improvement & Cost Savings

Led Lean and Six Sigma projects that resulted in quality and efficiency improvements:

oImproved PA66 Line1 A-grade quality (81.7% to 87.5%), saving $755K.

oImproved PET Line A-grade quality (85.1% to 93.5%), saving $456K.

oTwisting energy reduction project saved $40K annually.

oImplemented Lean Production, increasing capacity by 10% and reducing cost of poor quality (COPQ) by 10%.

Supply Chain & Project Management

Optimized supply chain, reducing lead time from 18.5 to 12.5 days and improving on-time delivery (96.8% to 99.1%).

Managed large-scale projects, such as:

oFabric expansion, increasing TW capacity by 3,500T/year and DIP capacity by 18,000T/year.

oDipped draw cord project for Nike, increasing daily capacity from 1,000 to 8,000 pieces.

Professional Experience

Senior Process Engineer

IVMS (Indorama Ventures Mobility Scottsboro, Former PHP Fibers Inc., USA) 2021 – 2025

Responsibilities: In charge process parameter setting and optimize process, work closely with production team and maintenance team to continuously improve production yield, product quality and reduce cost.

Optimized PET Line process, improving A-grade quality from 85.1% to 93.5%, saving $456K and winning 2nd place in the IVEX Americas Project Competition (2022).

Improved PA66 Line1 process A-grade quality from 81.7% to 87.5%, saving $755K and winning 1st place in the IVEX Americas & Global Project Competition (2023).

Enhanced PA66 Line3 A-grade quality from 79.3% to 85.1%, saving $821K.

Operations Manager – Twisting & Weaving

Performance Fibers Co. Ltd (Indorama, China) 2018 – 2021

Responsibilities: Lead a team including process, production and maintenance, work closely with safety, quality and other functional teams to achieve KPIs of safety, quality, yield, productivity and cost.

Led a team of 300 employees, achieving 1 million man-hours without OSHA incidents.

Improved Yield from 98.8% to 99.2% and Full Package Rate from 96.5% to 97.5%.

Implemented automation in cabling, increasing productivity by 5%.

Operations Director

Guangzhou All Victory Grass Co. Ltd. 2015 – 2018

Led expansion project on selection and installation of equipment (machine of extrusion, twisting, tufting, coating, testing) and put into production successfully in new plant, successfully increasing output and efficiency by 31%

Assistant to Chairman

Guangdong Yilong Advanced Material Technology Co., Ltd. 2014 – 2015

Improved A-grade product quality from 93.5% to 96.5%, reducing scrap from 8.2% to 7.7%.

Consolidated three workshops, reducing costs by 10%.

Label Factory Manager

Guangdong Esquel Textiles Co., Ltd. 2010 – 2014

Led factory operations, achieving quality and efficiency improvements.

Optimized production schedules, improving on-time delivery (OTD) from 96% to 99%.

Production Manager – Fibers & Fabrics

Performance Fibers (Kaiping) Co., Ltd. / Honeywell / AlliedSignal (China) 1996 – 2009

Led expansion project on selection and installation of equipment (machine of twisting, weaving, dipping) to increase capacity (Twisting, Weaving-3500mt/yr, Dipping-18000mt/yr)

Managed fiber and fabric production, implementing Lean and Six Sigma methodologies.

Education

Bachelor’s Degree in Applied Chemistry

South China University of Technology

Certifications & Awards

Six Sigma Green Belt Certification – IVEX (2022), Honeywell (2000)

Lean Expert Certification – Honeywell (2004)

Lean Manufacturing & Continuous Improvement Training

Awards: IVEX 1st Place (2023, PA66 Line 1), IVEX 2nd Place (2022, PET Line), Honeywell Asia Pacific QFE (Quest for Excellent, 2002), Honeywell Premier Achievement (2000)

Technical Skills

Process Optimization (DMAIC, C&E, FMEA, SPC, VSM, SMED)

Quality Management (ISO 9001, ISO 14001, TQM)

Health, Safety, and Environment (HSE) Compliance

Production Planning & Execution

Leadership & Team Development

Supply Chain & Cost Reduction Strategies

Contact this candidate