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Maintenance Manager

North York, Canada
August 15, 2012

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** ******* ****, ************, *******, K0L 1L0 Phone: 705-***-****



Results oriented Professional Engineer with strong engineering, maintenance, environment, health, and safety management skills. Excellent problem solving and project management skills with a proven record of reducing costs and improving operations through continuous improvement. Solid leadership, communication, and team building skills.


HORIZON PLASTICS CO. LTD., Cobourg, ON 9 years (2002 to 2005 and 2006 to present)

A custom structural foam injection molding company for the consumer, commercial and industrial markets. The company employs 250 people in a 24/7 manufacturing operation.

Engineering Manager, Maintenance and Plant Engineer.

Reporting to the President, responsible for engineering, facilities, capital projects, Pre-Start Health and Safety Reviews, Hazard Analysis, Certificates of Approval. Team Leader for a group of five engineers and technologists.

• Product design, tool repair and modifications, new product development and startup. Last year our engineering team brought five new products into production.

• Recently completed a $3.5 million machine installation. The machine is a 2500-ton horizontal injection molding machine, the largest of its kind. It is producing 4 by 8 sheets of lattice at a rate of 6 sheets per minute.

• Rebuilt, modified and installed five horizontal injection molding machines. Installed cost $1.5 million each. Machines were installed in less than half the time previous machines had been installed. Company was able to bring products to market several months sooner than expected.

• Completed an 8,000 square foot dock expansion, a 9,000 square foot office expansion, installed a 3,000 KVA substation transformer and switchgear, and upgrades to chilled water and compressed air plant systems.

IKO INDUSTRIES LTD., Madoc, Ontario 2 years (2005 to 2006)

A Canadian multi-national roofing products company. The Madoc facility is an open pit mining operation that manufactures coloured granules for the asphalt shingle industry and employs 80 people in a 24/7 manufacturing operation.

Project Engineer

Reporting to the Plant Manager and responsible for a $15 million plant expansion including a 25,000 square foot four storey building, 4 large rotary units, 7 belt conveyors, 4 bucket elevators, 34 screw conveyors, 4 dust collectors, 8 silos, 6 batch tanks, 20 pumps, and 3 compressors. Managed a 14 member project team including designers, engineers, and supervisors. The work included detailed design, drawings, specifications, tendering, contract administration, and construction. The plant expansion involved the construction of a complete new granule colouring line and increased overall capacity from 70 to 105 tons per hour.


A wire and cable manufacturer of a wide range of products for the industrial market employing 300 people on continental shifts in a cellular manufacturing environment. Over 80 production lines including a wire mill.

Engineering Manager 3 years (1999 to 2002)

Reporting to the Plant Manager, responsible for all engineering, maintenance, environmental and manufacturing process issues. Led a 7 member multi-disciplined team of engineers, and a maintenance group consisting of two supervisors, a planner, and 22 skilled unionized maintenance personnel with a $2.8 million maintenance budget. Responsible for a 250,000 square foot manufacturing/office facility, and a 65,000 square foot warehouse distribution facility. Responsible for managing a $1.2 million capital program.


• Developed and managed corporate cost reduction program using a team approach to identify opportunities, brainstorm solutions, develop and monitor action plans, and recognize and reward group/individual successes. Implemented over 40 different projects which generated annual cost savings of over $2 million.

• Organized a problem solving team consisting of hourly production and maintenance employees, an Engineer, and a Facilitator to address a production capacity problem on intermediate drawing, resulting in the need to out-source production. Identified issues, alternatives, and developed a business plan for a capital project of over $2 million which generated projected savings of over $600,000 annually.

• Established and led a cross-functional team to implement an internet based Computerized Maintenance Management System. The team planned implementation, maintenance, priorities, action steps, responsibilities, and deadlines. Hardware and software implementation, system functionality, training, data transfer, start up, and debugging were completed on time. After installing the new system spare parts inventory was reduced from $800,000 to $500,000. Staffing was reduced by 5 people, and service to in-house customers was improved.

Maintenance Supervisor 2 years (1997 to 1999)

Reporting to the Engineering Manager, led a group of 27 skilled and non-skilled maintenance personnel in a fast paced unionized manufacturing environment. Day to day management of all maintenance activities, including an $800,000 maintenance storeroom. Strong emphasis on planned, preventative, and predictive maintenance programs.

• Led regular crew meetings for training, safety, key issues, changes in procedures, machine shop priorities, and problem solving. Reorganized staff assigning a mechanic to each cell, assigning two people to work on breakdowns, with the balance on Preventative Maintenance (PM’s) and projects. Maintenance downtime decreased from 18% to 14%, 100% percent of PM’s were completed on time and as scheduled, outsourcing labour for project work was reduced, and teamwork improved.

Facility Engineer 2 years (1995 to 1997)

Reporting to the Engineering Manager, responsible for civil and mechanical facilities engineering, including boilers, compressed air, chillers, cooling towers, process water pumps, ventilation, sprinklers, alarm systems, roofing, buildings, and grounds. Responsible for environmental issues, including Certificates of Approval (Air), waste water sampling, sewer by-law monitoring, National Pollutant Release Inventory reporting, Transportation of Dangerous Goods, registered hazardous and industrial waste disposal, spill control, response, and training.

• Developed an in-house computerized maintenance management system using the AS400 network of computer terminals, with the support of the I.S. department. Debugged system, trained personnel, and wrote a maintenance manual. System provided for maintenance work orders, itemizing and prioritizing work orders, planning maintenance objectives, measuring maintenance performance, a historical record of work completed, a method of scheduling PM’s, and monitoring their completion. PM's were completed on schedule 80% of the time, more project work was completed, there were fewer breakdowns, equipment calibrations were documented, and the system achieved ISO certification.

• Devised a new office heating system that used a gas fired hot water boiler and a mixing valve in the hydronic loop. Cost savings were $15,000 annually, resulting a 3-year pay back.

• Managed an electrical switch gear and distribution system project to increase capacity for new production equipment. Learned about electrical switch gear and distribution systems. Worked with equipment suppliers to develop a detailed design for the project. Negotiated contracts, supervised the building construction, equipment installation and startup, and completed project ahead of schedule and under budget.


3M CANADA INC., Havelock, ON 7 years (1988 to 1995)

The Havelock facility was an open pit mining operation that manufactured of coloured granules for the asphalt shingle industry, aggregates for the paving industry, and hollow glass bubble filler for the plastics industry employing over 100 people on a 1,000 acre site with a 50 acre open pit mine, crushing and screening plant, colouring plant, and bubble plant.

Maintenance General Supervisor, Plant Engineer

Reporting to the Plant Manager, initially hired as Maintenance General Supervisor. Responsibilities expanded and title changed in 1991. Responsible for all engineering activities, maintenance, environmental, health, safety, and security activities as well as all facilities and grounds. Managed a 25 member maintenance staff, including millwrights, electricians, and heavy-duty diesel mechanics as well as two supervisors, a maintenance planner, and a health & safety coordinator. Indirect reports included a project engineer assigned by head office.

• Project Manager for a $6 million crushing plant expansion. Supervised detailed design, preparation of drawings and specifications, tendering, contract administration, construction. Project was completed on schedule during difficult weather conditions and within budget. Plant capacity increased from 200 to 600 tons per hour. Production output exceeded project targets and product quality exceeded customer requirements.

• PM programs, detailed maintenance costs, and cost justified the replacement of several units. Plant run time improved each year after the new system was implemented and maintenance costs were 99 percent of forecast.

• Appointed to lead $1 million colouring plant automation project. Revised initial project, supervised design of the new processes and construction and installation drawings, managed equipment specifications, selection, purchasing, construction, installation, startup and training. Project was completed on schedule, within budget and with no major interruption to manufacturing. Plant capacity increased from 60 to 100 tons per hour and automated controls reduced operators from two to one.

• Demonstrated coaching and counseling skills to assist supervisors and reassigned positions and job duties to better suit their skills and competencies resulting in a promotion for one individual, reassignment to a staff maintenance position for another, and an expanded role to provide additional challenges for third person.


• University of Western Ontario - Bachelor of Engineering Science

• Professional Engineers of Ontario – P. Eng. Designation

• Power Transformers, Power Systems Services Group, Toronto

• Motors: Applications and Maintenance, Ainsworth, Toronto

• Predictive Maintenance Programs, Ainsworth, Toronto

• Maintaining Electrical Power Distribution in Buildings, Ainsworth, Toronto

• Understanding Arc Flash PPE Requirements, Electrical Safety Authority

• Pre-Start Health and Safety Reviews, Resource Environmental Assoc., Toronto

• Machine Process Safeguarding, Resource Environmental Assoc., Toronto

• Inspecting and Maintaining Steel Storage Racks, C.S.A. and I.A.P.A, Kingston

• Safeguarding of Machinery, C.S.A and I.A.P.A., Ottawa

• Fall Protection / Aerial Lift Platform / Overhead Cranes, Ryder Machinery Ltd, Belleville

• Hazard Identification and Workplace Inspection, Industrial Accident Prevention Assoc., Cobourg

• Ontario Electrical Safety Code, Loyalist College, Belleville

• AutoCAD, Loyalist College, Belleville

• Computer skills including: MS Word, Excel, PowerPoint, Microsoft Project, AutoCAD

• Facilities engineering and maintenance: civil, mechanical, some electrical

• Manufacturing, maintenance, engineering, management, capital engineering, and project management

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