Project Manager Process Engineer

SUMMARY

Safety-minded, people-first, principle and data-based, customer satisfaction and results driven pulp & paper machine technical process engineer, project manager, and operations engineer and manager with 20+ years of experience. Led all aspects of manufacturing specialty/dissolving wood and cotton linters pulp/paper sheets in fast-paced, high production rate environments with stringent quality demands, including supervision of hourly technicians. Excelled in process design, optimization and troubleshooting using SPC, DOE and data analysis, technical project management, customer service, continuous improvement, and risk analysis (FMEA, etc.). See “Skills” at the bottom of Page 2 for the many accumulated. Led process design and equipment specifications, installation, and optimization of processes for projects to replace or upgrade paper making processes from stock prep through finishing lines. Ready to learn and contribute to the efficiency of your processes, projects, and/or quality assurance and ISO systems!

EXPERIENCE SUMMARY

Home Repair Leader 12/2023 – Present Perry, FL.

Due to excessive hurricane damage late August 2023, after the GP closed the mill, took time off to plan and oversee the crews sent to replace the roof and soon to replace the windows and use my skills – carpentry, fencing, plumbing, and electrical work. I will be able to sell the house soon, so I am ready to start in a position I am enthusiastic about.

Please note that Proctor & Gamble Foley Cellulose, Buckeye Florida Cellulose, Buckeye Technologies, Buckeye Cellulose LLC, and Georgia Pacific Foley Cellulose, all owned this mill, respectively, in Perry, Florida, which was where I worked or was based during my tenure listed below.

Senior Process and Quality Manager 01/2020 - 11/2023 Georgia Pacific Cellulose Perry, FL

As the SME (Subject Matter Expert) for the paper machines, led, approved, and/or participated in all proposed changes to paper machine processes and product design, projects large and small, equipment, continuous improvement trials and troubleshooting. Co-holder of two US patents for the manufacture of two separate specialty products.

Participated with other process managers to change bleaching design and equipment to eliminate elemental chlorine. Led risk analysis in the paper machine area and the mill wide team on risk analysis

Led troubleshooting using Kepner-Tregoe, Fishbone, 5s, and RCA investigations, CAPA’s, SPC, Lean Manufacturing, i.e., SPC, DOE, Data Analysis

Designed and implemented the machine setups to optimize sheet properties for each grade. In one case, which was only changes in how the sheet was formed on the paper machine, it resulted in a new grade that made a $4.5MM annual profit increase.

Developed machine parameters of all grades. One example of the benefit was for a severely softened pulp for filters -- improved internal reliability by 35% and first quality acceptance by 20% with zero cost.

Superintendent of Paper Machines and Stock Preps 01/2017 - 12/2019 Georgia Pacific Cellulose Perry, FL

Successfully managed the 3-4 engineers and 50+ operators required to operate the two paper machines and stock preps in the areas of safety, cost, quality, production, maintenance, and people development.

Forecast the annual and monthly forecasts for the costs of the areas listed above for the following fiscal year.

Tracked monthly against the current budget, adjusting as necessary to meet the annual budget.

Viewed and reported Key Performance Indicators (KPI’s) to upper management weekly and monthly.

Using developed process and product knowledge business acumen and the Voice of the Customer (VOC), formed and led a team to study KPI’s and identify and present key capital projects to the Mill Capital Team, then participated in the meeting of said team that set priorities for all areas of the mill with the funds allocated.

Managed and coached engineers career progression, training, finding a mentor, etc., as well as developing the technical and people skills of the operators.

Performed Quality Manager (below) and Senior Process Engineer (see above) roles also.

Sr. Product Development (Process) Manager 08/2013 –12/2016 Georgia Pacific Cellulose Perry, FL

This role was the same as the Senior Process Development Manager and Quality Manager as described above.

Planned and executed process and product development trials, collaborating with Product Development, Product Managers, and Sales to create new products, enhance existing ones, and address customer issues.

As the paper machines area Technical Project Manager led process design, equipment specifications, selection, and cost at each gate for an extensive wet end rebuild. Led design, installation, start up, commissioning, and optimization. This resulted in decreased sheet strength (mullen) by 27% (target of the project), which enabled the use of our fluff pulp worldwide as equal to most competitors’ fluff pulps, instead of just in North America. Also, the weight profile variability decreased by 75%.

Process Development Mgr. and Paper Machine Technical Mgr. plus Quality Mgr., Operations Mgr., and Superintendent. 12/1997 - 07/2013 Buckeye Technologies, LLC Perry, FL

First two positions listed above actually ended when the mill shut down in 2023.

Provided technical support for projects at four sites in the capacity of a corporate consultant. Decreased variability and increased reliability in each. When the projects were in Perry, FL. was Technical Project Manager.

Presented the Voice of the Customer (VOC) to ensure customer needs are always met in the manufacturing process.

Planned and executed process and product development trials, collaborating with Product Development, Product Managers, and Sales to enhance products and address customer concerns.

Designed, led installation and startup, then optimized a new specialty pulp machine in Brazil, exceeding production and quality forecasts. We met or beat all startup targets, and even though none of the operators spoke English, we had ZERO recordables.

Delivered training sessions on principled-based operations and reviewed equipment/process changes across three sites. Used Lean Manufacturing and Kepner-Tregoe Troubleshooting to improve efficiency and eliminate waste.

Quality - Managed daily quality and historical data to satisfy customers, ISO 9001 compliance, and continuous improvement.

Reviewed in-process and KPI quality to solve process and equipment problems, determine root causes for customer complaints, and share actual data with customers.

Led continuous improvement, capital project expenditures, reliability projects, and quality uniformity initiatives to reduce variability.

Participated in internal (led) and external ISO 9001 audits.

Detailed Draftsman/Project Manager 05/1980 – 01/1983 Quality Fabrication & Machine Shop Lake City. FL

The company built and installed log yards and all types of sawmill conveyors, sweep kickers, etc. in the southeast.

I started out as a welder’s helper, then was taught to cut and weld, use the press brake and hole punch and was then promoted to layout person inside the shop when my affinity for it surfaced.

Completed a drafting course at Lake City Community College (now Gateway College) and became a detailed draftsman in the office. Took the next drafting course and became a certified draftsman the next semester.

Became a Project Manager while still detailed drafting, took more drafting courses.

OTHER EXPERIENCES

Paper Machines Quality Manager Buckeye Florida Cellulose Perry, FL

Paper Machines Operations Manager Buckeye Florida Cellulose Perry, FL

Paper Machines Process Manager Proctor & Gamble - Buckeye Cellulose Perry, FL

Pulp Drying Team Manager P&G Foley Cellulose Perry, FL

Project Engineer P&G Cellulose Perry, FL

SKILLS

Safe Start, Paper Making Principles, Process Modeling using Excel and Win Gems, Process & Energy Balances, Process Optimization, Risk Management Technical Project Management, Lean Manufacturing including LSW (Leader Standard Work), PFMEA, and Kepner Tregoe, Fishbone Diagrams, Five Whys and other trouble-shooting methods, Micro Soft Office Suite, Project Management, Customer Service, CAPA, Voice of the Customer, Continuous Improvement, Product Development, Design of Experiments, Data Analysis, Quality Control, ISO Quality Systems, Familiar with DMAIC, OSHA regulations, Process Safety Standards, TAPPI Test Methods, ISO 9001 & Internal & External Audits, Micro Soft Office Suite including Excel, Outlook, PowerPoint, Word, Project Management, Gantt Charts, Aspen Tech, Pi and Process Book, Project Management Process, P&ID’s, Loop sheets, Blueprints, Dimensioning, Redlines, and general environmental regulations. Have used some— Microsoft Project, Visio, and AutoCAD. Statistical Process Control and D.O.E., DCS, Priority Setting, Multitasking, Coaching, Supervising Personnel, Presentations, and many others.

EDUCATION

B.S. Mechanical Engineering with Honors, University of Florida in Gainesville, FL.

AA in Pre-Engineering, Lake City Community College in Lake City, FL.

Qualifications & Certificates from TAPPI Short Courses (list not meant to be all inclusive)

Introduction to Pulp & Paper, TAPPI Wet End Short Courses (several times), Statistical Process Control in real processes, Advanced Statistical Control including Design of Experiments (DOE), Internal ISO Auditor, Fiber Physics TAPPI short course.

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