Plant/Operations Manager

Jon F. Bryan 832-***-**** (cell)

Piedmont, SC *9673 ******@*******.***

AREA OF EXPERTISE:

Ops/Engineering- Operational Efficiency, and Engineering Management

Plastics-Plant Management, Processing and Development

Product Development: Design and Circularity, Sustainability

EXPERIENCE:

2/24 – 2/25: Plant Manager/ Operations & Engineering Manager, Verdeco Recycling Group, Piedmont, SC

Company is a manufacturer of over 200 mm RPET- Piedmont a greenfield facility

Responsible for 3 USA Facilities that produce FDA rPET utilizing conical twin and single screw extrusion/SSP Lines

Commissioned 2 rPet Starlinger Bottle-to-Bottle lines in Piedmont.

Established standardized processes across 3 plants creating equal quality using different equipment.

Responsible for Safety, Process, Engineering, Maintenance, Quality, and Commercialization functions.

Flake characterizations and BOM control, raw material qualifications, LNO FDA compliance

Process Design, CAPEX planning, Maintenance PM and spare parts, Operations efficiency, over-all Plant KPI

Established KPI driven metric targets, interdepartmental focus teams, inventory variance teams

Gap analysis performed and conversion from reactive to predictive maintenance.

Annual Maintenance budgets and Capex planning, and capacity by sku matrix modeling for OTD. OEE tracking and use of defect data for CI initiatives.

Established Energy conservation focused Process and Maintenance standards.

60% growth in 2024, and multiple New OEM qualifications- blown bottles, hot-fil, ESBM, and sheet applications.

7/23 – 1/24: Technology Manager, Avgol Non-Wovens, Mocksville, NC

Company is a manufacturer of over 140mm pounds of Non-woven PP

5 Reicofil Spun/Blown Extrusion Lines, 2 Erema Lines, and $100 mm expansion for line six- Q2 2024

Supported 5 Process Techs, Engineering, Maintenance, Quality, and Product Development functions.

Data driven focus on KPI improvements, Risk/Gap Analysis, Reliability, and Quality Improvements

4/16 – 7/23: Sr. Process Engineer, Samuel Packaging Systems Group, Fort Mill, SC

Company is a manufacturer of over 60 mm pounds polyester strapping from recycled PET

Resin systems include RPET polyesters, engineered resins, and polymer additives.

Responsible for process monitoring, statistical capabilities, and CI related to process, lower cost BOM, and quality needs. Scrap rate reductions of 18% in past 3 years. OEE gains of 25%.

Part of team implementing and commissioning filtration machinery by Erema, and Starlinger SSP polymerization.

Responsible for monitoring production performance trends and identifying root causes of manufacturing process defects.

Capital Project Management of over $20mm in 2 years, including installation of new extrusion lines in GA and SC

5 Year capability planning and implementation of capital to support ROI.

Product Development and Patent identification/licensing opportunities; US and International efforts.

Facility Capacity Planning, Budgeting, Commercial Development Planning Support, and Capability Planning.

1/15 – 1/16, Technology and Process Engineer, Sukano Polymers, Duncan, SC

Company is a manufacturer of functional additive and masterbatch for the packaging industry. The sectors include mono and multi-layer films, blown and oriented film, profile extrusion, oriented films, and cast markets.

Products are produced utilizing Leistritz twin screw extrusion systems.

Resin systems include polyesters, biopolymers, engineered resins, and olefins.

Savings of over $250,000 realized within the first 6 months of employment in areas of scrap reductions and first-pass yield improvements.

50% reduction in customer complaints in 2015.

2/14 – 1/15, Operations Manager, Intergroup International, Euclid, OH

Responsible for all aspects of the operations of 95 million pound- zero waste recycling facility.

Processes included: consolidations and sortation, size reduction and grinding, densification, Erema extrusion, baling, slitting, pulverizing, and waste to energy processes.

Operations in Georgia and in Ohio, with over 100 direct reports- closed in Spring 2015

10/9 – 2/14, Lab Manager, Ravago, Waller, TX

Responsible for all laboratory/technical and process functions for a facility that produces over 80 million pounds of extruded PE and CoPP product utilizing 4 Erema extrusion lines.

Was responsible for formulations and production/equipment processes, production daily goals, technical procedures and training, customer COA’s, complaint response and route cause investigations, and departmental P&L.

Reduced slow moving inventory by over 4 million pounds within 2 years.

7/07 - 10/09, Contract Positions

Quality Engineer, Myco Plastics, Jacksonville, TX 3/09 - 10/09

Manufacturing Specialist, TMAC - University of Houston Dept. of Technology, Houston, TX 7/07 - 5/08

6/06 - 7/07, Quality Systems Manager / Process Engineer, Alloy Polymers, Inc., Richmond, VA

All laboratory functions, ISO 9002 and TS-16949:2000 and ISO 17025, primary contact for external auditors and performed internal audits to identify corrective/improvement opportunities. All ISO certifications were successfully renewed during tenure.

Process Engineer in charge of all color toll compounding and color match.

9/00 - 5/06, Opti-Blast, Inc., Jacksonville, TX,

Vice President, 9/03 - 5/06

Additional responsibilities included P&L, payroll, census, and capital equipment acquisitions.

Plant Manager, 9/00 - 9/03

As Plant Manager, was responsible for all plant personnel, safety, maintenance, operating expenses, raw material scheduling, shipping and receiving, inventory control, and P&L.

Worked with sales staff to identify and recommend product type and operating parameters to meet customer expectations and needs.

Over-Seas raw materials and vendors were identified and qualified to reduce costs.

Maintained all Military approvals on Mil-P-85891-A and monitored RFQ solicitation SOW, including protest filings/defense through GAO.

Developed and maintained plant environmental compliance in recycling and handling of hazardous spent abrasives in accordance to 40 CFR and TCEQ guidelines.

Growth over the 6 years was 325% with raw materials cost drop of 35%, and 2 new military approved abrasive products.

Manufacturing efficiency improved 46%.

10/95– 4/00, Senior Color Engineer/ Lab Manager, World-Pak Masterbatch, Lolita, TX

Startup Development Engineer of 25MM pound per year masterbatch facility marketed to blown film, cast film, thermoform, BOPP, profile and injection molding companies. Worked with PP, PE and Styrenics.

Color/Additive formulation development for film and sheet applications, pigment pallet reductions, over-seas sourcing, quality control parameters, and customer complaint evaluations.

Responsible for: quality systems, training, development of color and additive masterbatch, 2 million dollars in laboratory equipment requisitioned, including customer complaint evaluations and troubleshooting,

Production standard operating procedures development (SOC), laboratory network database development for internal documentation control, ISO 9001/9002 preparations (completed after employment ceased), process/screw design and recommendations.

Formulated products based upon the capabilities of production and recommended changes to improve processes and cost performance (5 twin screws and 1 continuous mixer).

50% growth over two years and 40% reduction in cost of stock products.

22 people managed, including QC, color, R&D, and technical.

8/92 - 9/95, Production Manager, Teknor Color, Jacksonville, TX

Managed production including labor force, production scheduling based on inventory availabilities (98% on-time shipment ratios,) established SOC for production extrusion, maintenance scheduling and general production performance needs.

Single screw extruders, strand and underwater pelletizing.

1987-1990 various QC support roles- color match, quality, physical testing while attending college.

EDUCATION

1991, BS Physics (minor in Chemistry & Math), Angelo State University

1995, Graduate School of Sciences (Industrial Technologies towards MS), University of Texas at Tyler

2007, TS- ISO-16949-Internal Auditor Training- Fintech

2007, 5S Lean Tools- Fintech

2008, Sig Sigma Green Belt Training- UH

2008, Lean Manufacturing- Train the Trainer- UH

2013, Dale Carnegie leadership and Management Series- Ravago

2017, Behavior Safety Training- Samuel

2023, Quality Systems Design- Proctor & Gamble

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