Predictive Maintenance Continuous Improvement
Resume:
Robert J. Cousins
***********@*****.***
Professional Summary
Results-driven maintenance and operations leader with over 25 years in high-speed, heavy industrial
manufacturing, including pulp, paper, and tissue production. Proven track record of improving safety,
reliability, and uptime while managing large, multi-disciplinary teams in 24/7 environments. Experienced
in preventive and predictive maintenance, root cause analysis, and lean manufacturing systems.
Successfully led capital projects ranging from $40K to $40M, delivering measurable improvements in
cost, efficiency, and production throughput.
Key Skills
• Maintenance & Reliability Leadership (24/7 operations)
• Preventive & Predictive Maintenance (PM/PdM)
• Root Cause Failure Analysis (RCFA)
• Lean Manufacturing & Continuous Improvement
• PLC & Electrical Systems Troubleshooting to include allen bradley, abb, and Siemens
• Budgeting & Cost Control
• CMMS Utilization & Performance Tracking
• Capital Project Management ($40K–$40M)
• Safety & Environmental Compliance
Professional Experience
Kruger – Memphis, TN
PM 5 TAD Operations Superintendent Jun 2023 – Jun 2025
• Directed four shifts to ensure safe, consistent operations of the TAD tissue machine with focus
on uptime, reliability, and safety.
• Improved OEE by 1.5% by enhancing inter-shift communication and implementing Centerline
and Cleaning/Inspection/Lubrication (CIL) processes.
• Achieved two favorable budget months in 2025 through disciplined cost control and operational
improvements.
Sofidel – Haines City, FL
PM Maintenance Manager Oct 2021 – May 2023
• Managed maintenance for two tissue machines and CHP department; oversaw CHP operations.
• Planned and executed major and recurring outages with minimal downtime.
• Implemented predictive maintenance programs including vibration analysis, lubrication routes,
oil analysis, RCFA, and thermal scanning of electrical cabinets.
CHP Supervisor Jun 2021 – Oct 2021
• Led four shifts in implementing lean techniques to improve electrical generation and reduce fuel
costs.
Eaton (Greer Temp to Perm) – Arden, NC
Assembler Jan 2020 – May 2021• Assembled and wired industrial breakers using lean techniques to ensure quality and meet
production goals.
Evergreen Packaging – Canton, NC
Recovery Manager Mar 2018 – Nov 2019
• Improved safety and reliability through behavior-based systems; achieved 1M safe man-hours in
Aug 2018.
• Increased efficiency in evaporators and white liquor production through targeted capital
improvements.
Almatis – Burnside, LA
Superintendent Precipitation / Powerhouse Superintendent May 2017 – Mar 2018
• Restored production post-incident using lean systems to improve KPIs.
• Increased throughput from 2,400 to 4,200 GPMM.
• Reduced contract labor costs and hydro-blasting expenses through resource optimization.
International Paper – Rome, GA
Assistant Process Manager Oct 2014 – Mar 2017
• Improved safety, reliability, and cost performance across Recovery, Evaporator, Turbine, Water,
and Power departments.
• Led initiatives that achieved the 2nd-best throughput in company history for
recovery/evaporator operations.
Glatfelter Paper Company – Spring Grove, PA
Pulp Mill Superintendent – Continuous Improvement Dec 2013 – Oct 2014
• Applied lean techniques to enhance safety, quality, and production.
• Participated in a $100M project to replace coal boilers with package boilers and updated water
systems.
Weyerhaeuser Paper – Flint River, GA
Utilities Assistant Manager / Utilities Superintendent Aug 2005 – Nov 2013
• Oversaw evaporator, kiln/recaust, and wastewater operations, achieving significant cost
reductions and efficiency gains.
• Led capital projects including automation, fan upgrades, and water treatment improvements.
Georgia-Pacific – Brunswick, GA
Utilities Process Engineer / Relief Supervisor Aug 1996 – Aug 2005
• Reduced fossil fuel use through innovative fuel blend strategies, saving $280K annually.
• Coordinated safe and efficient lockouts, maintenance, and compliance programs.
Utility Process Engineer Jul 1992 – Aug 1996
• Led fuel savings projects and process optimization initiatives, earning the GP Chairman’s Award.
United States Army Officer Aug 1987 – Jul 1992
• Served as Captain and Assistant Operations Officer, overseeing deployment and logistics for 680
personnel during Gulf War operations.
• Awarded Bronze Star and Army Commendation Medal for meritorious service.
Education
University of Alabama – Tuscaloosa, AL
B.S., Chemical Engineering
• Distinguished Military Graduate, RO
Contact this candidate