Senior Engineer - Regulatory-to-Operations Translator
Resume:
Dan Kadlubar
Lake Charles, LA ***** 337-***-****
www.linkedin.com/in/dan-kadlubar-06849b3a5/ **********@******.***
Senior Engineer
Translate Regulatory Requirements into Practical, Executable Operations
Engineering leader with extensive industrial experience in safe, reliable, efficient plant operations, specializing in troubleshooting complex process issues, driving continuous improvement, and mentoring cross-functional teams to improve asset reliability, capital project support, and safety / compliance performance. Deep expertise spanning process safety management, waste treatment operations, derivatives production, logistics, and large-scale turnarounds, with proven ability to troubleshoot complex process issues and stabilize critical assets. Recognized for driving continuous improvement across safety, environmental compliance, training, and operational discipline while supporting capital projects and sustaining asset reliability.
Core Competencies:
Process Safety Management (PSM) & RMP Compliance
Waste Treatment & Derivatives Operations
Operational Troubleshooting & Root Cause Analysis (RCA)
Training Program Design & Workforce Development
Turnarounds, Shutdowns & Commissioning Support
Regulatory Audits & Environmental Compliance
Asset Reliability & Safe Operating Envelope (SOE)
Management of Change (MOC) Leadership
Cross-Functional & Frontline Leadership
Incident Investigation & Risk Mitigation
Professional Experience
WESTLAKE CHEMICAL, Lake Charles, LA
Previously Axiall Corporation (PPG Industries, Incorporation & Georgia Gulf Merger)
Senior Engineer, Waste Treatment Unit (WTU); Perchloroethylene & Trichloroethylene (Per / Tri), 2016 to Present
Provide senior engineering leadership for Plant B special projects, training governance, and process safety initiatives, supporting waste treatment and derivatives operations. Serve as trusted operational advisor to plant leadership, ensuring regulatory compliance, workforce readiness, and safe execution of high-risk activities while strengthening operational discipline across units.
Standardized plant-wide training frameworks to align instructional content, qualification requirements, and delivery methods, improving compliance consistency and strengthening operator readiness.
Directed Management of Change governance and validated technical documentation and implementation timelines, reducing procedural gaps and ensuring timely execution of approved modifications.
Maintained and refreshed operating procedures while mentoring new Unit Operator Trainers, accelerating onboarding effectiveness and improving knowledge transfer to frontline staff.
Advised superintendents and operating teams through hands-on coaching, strengthening decision-making quality and improving unit performance during routine and abnormal operations.
Defined roles and accountability using RACI methodology as Plant Management Team member, enabling clearer ownership and faster execution of complex, site-wide action plans.
Led safe coordination of operations, maintenance, and contractors during WTU turnaround night shift, achieving incident-free execution under high-risk conditions.
WESTLAKE CHEMICAL, Lake Charles, LA
Senior Engineer II, 2013 to 2016
Served as Process Safety PHA Team Leader (certified by Primatech) and Manufacturing Excellence Advisor Apollo RCA Facilitator (PSM Incident Investigation) MOC Coordinator Training Principles of Procedure Writing for PSM. Conducted comprehensive audits in Chlor / Alkali and Derivatives operations and maintenance in alignment with: Care Management System Guidelines, OSHA Process Safety Standards (29 CFR 1910), DOT Hazardous Materials Regulations (49CFR), Title V Air Permit Compliance, and EPA SPCC Requirements (40 CFR Part 112).
Functioned as ISO 9001: 2008 Lead Auditor, ensuring adherence to international quality standards.
Supported major incident investigations and enterprise-level process safety initiatives across Axiall South Complex, strengthening root-cause analysis, corrective actions, and risk mitigation outcomes.
Delivered structured instruction on 14 Elements of Process Safety Management within Basic Operator Training program and mentored early-career engineers, advancing technical competency and reinforcing strong safety culture.
PPG INDUSTRIES, Lake Charles, LA
Derivatives Compliance Engineer, 2012 to 2013
Provided regulatory and process safety oversight for high-risk chemical operations to ensure products, systems, and startup activities complied with federal regulations, industry standards, and internal governance requirements.
Led Pre-Startup Safety Reviews for Vinyl Chloride furnaces following major repairs and shutdowns, authorizing safe re-commissioning and regulatory readiness.
Facilitated cross-disciplinary engineering and operations teams to execute emissions-reduction strategy for South VCM unit, improving environmental compliance and operational performance.
PPG INDUSTRIES, Lake Charles, LA
Performance Engineer, Waste Treatment Unit, 2011 to 2012
Directed operational planning, process optimization, and outage coordination for complex waste treatment unit while balancing compliance, efficiency, and production demands.
Planned and executed multi-asset shutdown and inspection schedule aligned with internal requirements and downstream unit outages, minimizing production disruption and inspection risk.
Restored desuperheater steam service to BAT preheaters through targeted engineering intervention, increasing energy efficiency and system reliability.
PPG INDUSTRIES, Lake Charles, LA
Manufacturing Excellence Advisor, 2009 to 2011
Evaluated manufacturing performance, regulatory adherence, and risk controls to identify gaps and implement sustainable improvements across high-hazard production units.
Directed ISO 9001:2008 compliance audits as Lead Auditor, preserving site certification through successful multi-area evaluations.
Steered large-scale turnarounds for South VCM and TE-II units, achieving zero injuries and no environmental incidents during high-risk activities.
PPG INDUSTRIES, Lake Charles, LA
Supervisor, Shipping, Chlorine Rack, 2007 to 2009
Managed chlorine railcar logistics and shipping operations to ensure safe handling, regulatory compliance, and uninterrupted customer fulfillment.
Executed Responsible Care customer assessment audits for chlorine shipments, confirming adherence to safety, security, and regulatory standards.
Modernized shipment tracking by integrating logistics software platforms, eliminating redundant data entry, and improving operational efficiency.
Additional Positions Held:
PPG INDUSTRIES, Lake Charles, LA
Logistics Coordinator, South VCM
PPG INDUSTRIES, Lake Charles, LA
Unit Supervisor, South VCM
PPG INDUSTRIES, Lake Charles, LA
Logistics Coordinator / Performance Engineer, WTU & CPC
PPG INDUSTRIES, Lake Charles, LA
Unit Supervisor & Performance Engineer, WTU
PPG INDUSTRIES, Lake Charles, LA
Logistics Coordinator, Tri-Ethane II
PPG INDUSTRIES, Lake Charles, LA
Plant B Shipping Supervisor
PPG INDUSTRIES, Lake Charles, LA
Technical Assistant, Plant A Shipping
PPG INDUSTRIES, Lake Charles, LA
Project Chemist
Education
Bachelor of Science (BS), Chemistry, McNeese State University, Lake Charles, LA
Professional Development
Distillation Seminar, McNeese State University
Coaching for Peak Performance, DDI
Dale Carnegie Seven Habits of Highly Effective People
Franklin Covey Speed of Trust
Thermal Oxidizers & Process Burners, John Zink Institute
Communicating for Leadership Success
Supervisor Development - Managing Conflict
Practice of Leadership- Leadership Development
Six Sigma Lean Yellow Belt and 5S Training
Black Belt / Kaizen Team Experience
Process Mapping Training
Certifications
ISO 9001: 2015 Lead Auditor, DNV GL
ISO 9001: 2008 Lead Auditor, DNV GL
Memberships
Member, American Chemical Society
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