Maintenance Manager

MICHAEL REPKO P.Eng.

** ****** ****** **, **** Hawkesbury, NS B9A 2A7

Res: 902-***-**** • Cell: 902-***-**** • *****-*****@***.***

ENGINEERING AND MAINTENANCE

Foundry, Heavy Industry, Process, Automotive, Manufacturing

Over 21 years in Heavy Industrial and Manufacturing environments, 13 yrs in supervisory roles, and 7 in Maintenance and Engineering management positions. Balance of career development found in Project and Manufacturing Engineering working closely with maintenance, production, quality, safety, and accounting. Dedicated to continuous improvement and total productive maintenance / manufacturing (Lean Manufacturing).

CORE COMPETENCIES

•Managing and leading maintenance departments with up to (7) direct reports, and (39) maintenance technicians, required to maintain facilities up to 150,000 ft , budgets up to $1.8 mil.

•Supervising skilled trades, production workers, contractors, and Engineers, both union and non-union. This includes coaching, mentoring, communicating, and training as well as setting the example for safety, hard work, perseverance, and integrity.

•Managing and enforcing Safety/Regulatory Compliance Programs including Lock-out/Tag-out, Confined Space, Boiler & Pressure Equipment, Cranes, Elevators & Mobile Equipment.

•Greenfield site start-ups including building construction, equipment purchase and installation, commissioning, hiring personnel, setting up departments and spare parts.

•Hands-on Trouble-shooting and debugging of Allen Bradley PLC’s, electrical controls, hydraulic systems, pneumatic systems, natural gas and mechanical systems.

•Initial set-up or conversion, launch, training, and on-going support of Preventative and Predictive Maintenance programs utilizing CMMS, specifically SAP, Maximo, MP2, and QuickMaint.

•Managing continuous improvement and corrective action programs, as well as performing detailed root cause failure analysis of various process, mechanical assembly, and manufacturing equipment.

•Managing several projects simultaneously, up to $9.8 mil, from funds justification through concept development, design, build, install, and commissioning, then PM and spare parts set-up.

•Proficient with AutoCAD, Access, VBA, and Word. Especially proficient with MS Project and Excel to generate reports, track project timing and budgetary spending.

PROFESSIONAL EXPERIENCE

QUALITY ASSURANCE ENGINEER – REGULATORY COMPLIANCE March 2009 – Present

NEWPAGE CORPORATION, Port Hawkesbury, Nova Scotia

Newsprint & Super Calender Paper Manufacturer

Responsible for compliance to government regulations mill wide including, but not limited to cranes, pressure piping, pressure vessels, ASME code regulated repairs, structural steel repairs (CWB), elevators, and lifting equipment.

•Developed Quality Plan Manual for maintenance and repair of boilers and pressure equipment, approved and registered with the Nova Scotia Department of Labour.

•CWB Certified Welding Supervisor & Level 1 Welding Inspector, organized and managed company CWB certification, and certification of all plant maintenance welders.

•Utilized SAP maintenance software for scheduling and planning of all required regulated maintenance and inspections of pressure vessels, pressure relief valves, elevators, cranes, and various other required annual inspections.

•Managed maintenance of Rail siding, Fire Protection water mains, yards and roofing.

ENGINEERING & MAINTENANCE MANAGER JUNE 2008 – JAN 2009

THOMAS MAGNETE CANADA INC, Cambridge, Ontario

Manufacturer of valves for automatic double clutch transmissions

Responsible for building, testing, calibrating, and commissioning of $8 mil of new equipment, however company declared bankruptcy due to loss of only major contract.

MAINTENANCE SUPERVISOR / ENGINEER OCT 2007 – JUNE 2008

KAISER ALUMINUM, London, Ontario

Supplier of Aluminum extrusions to Automotive Tier 1, 100,000 ft

Responsible for all maintenance activities within the plant, in addition to designing (AutoCad) and implementing Engineering changes to production equipment, to improve quality and OEE.

•Directly supervised Maintenance Planner, Maintenance Leader, (8) Millwrights, and (7) Electricians.

•Launched new Maximo system to meet TPM requirements, including data conversion, set-up, full work order/PM implementation, and training of all plant personnel.

ENGINEERING & MAINTENANCE MANAGER APR 2005 – JULY 2007

MATALCO INC, Brampton, Ontario (Restructured)

Supplier of prime quality 6000 series log and billet to extruders, 100,000 ft

Responsible for installation and commissioning of all equipment at a green field site, then set-up of maintenance department and PM/Work Order system to maintain all plant equipment and facilities.

•Direct/Indirect reports include a Process Engineer/Maintenance Supervisor, Electrical Controls Engineer, Preventative Maintenance Coordinator, and (7) maintenance technicians (Non-Union).

•Completed commissioning and start-up of homogenizing and saw line after OEM declared bankruptcy and walked off the job, including reprogramming automation (RSLogix 5000) and many mechanical process improvements.

•Ramped up production from 65,000 lbs per day to over 520,000 lbs per day

•Developed budget, then managed all purchase orders generated by the Maintenance department.

•Implemented many process improvements aimed at product quality and increased productivity.

•Participated on JHSC as a WSIB certified member.

MAINTENANCE MANAGER JUNE 2002 – MAR 2005

INTERMET, NEW RIVER FOUNDRY, Radford, Virginia (Declared Bankruptcy)

Supplier of Municipal and Automotive Tier 1 nodular iron castings, 150,000 ft

Responsible for maintaining all plant facilities, buildings, services, production equipment, mobile equipment and environmental controls required to meet daily performance goals and quality targets.

•Direct/Indirect reports included a Preventative and Predictive Maintenance Manager, Maintenance Expediter, and (6) Maintenance Supervisors, (35) Maintenance Mechanics, (4) Technicians (Union).

•Developed new weekend scheduling system, for all maintenance activities, to target priority work orders, PM’s and fully utilize available resources. Increased PM completion by 20%.

•Revamped the Predictive and Preventative Maintenance program to completely integrate Maximo into the planning, scheduling, and reporting process. Predictive program included vibration analysis, thermo-graphic imaging, and oil sampling.

•Filled in as Electrical Technician as required. (Electrical Technician on maternity leave)

•Developed and managed training programs for all maintenance employees with special emphasis on Lock-out/Tag-out, Confined Space, and Elevated work. Created many of the Lock-out procedures.

•Developed and programmed new computerized system for generating and tracking purchase orders. (Excel front end on a Access database, utilizing Visual Basic)

•Planned all major maintenance shutdown activities using Microsoft Project.

ENGINEERING & MAINTENANCE MANAGER AUG 2001 – APR 2002

GREDE FOUNDRIES INC., Wichita, Kansas (Restructured)

Supplier of Automotive Tier 1 nodular iron castings, 80,000 ft t

Responsible for maintaining and upgrading of all plant facilities, equipment and services including environmental controls.

•Direct/Indirect reports included an Environmental Engineer, General Supervisor, and Store Room Supervisor, Maintenance Planner, Maintenance Clerk, (3) Maintenance Supervisors, and (30) Maintenance Mechanics (Non-Union).

•Managed training and enforcement of safety program including Lock-out and Confined Space.

•Collected and organized data required to submit regular reports to Corporate.

•Participated in regular quality meetings aimed at scrap reduction.

•Developed and installed revolutionary system for verifying the addition of Magnesium into the treatment ladle by detecting the flare-off optically.

FACILITIES & MAINTENANCE MANAGER SEPT 2000 – MAY 2001

STANDARD INDUCTION CASTINGS, Windsor, Ontario (Plant Closed)

Supplier of ductile and grey iron casting, 75,000 ft

Responsible for maintaining and upgrading of all plant facilities, services and production equipment including environmental controls and powered vehicles.

•Direct/Indirect reports included three maintenance supervisors, a maintenance planner, and (20) Maintenance Mechanics (Union).

•Initiated launch and continued support of the Preventative Maintenance and non-production stores inventory control programs utilizing MP2.

•Championed continuous improvement, Increased Sinto Mold Line productivity by 20%.

MANUFACTURING ENGINEER AUG 1999 – SEPT 2000

KAUTEX-TEXTRON, Windsor, Ontario (Restructured after Take-over)

Tier 1 Supplier of plastic blow molded fuel storage systems

Managed all process improvements with respect to the GM T800 fuel systems produced on three manufacturing cells at the Kautex Windsor facility, volumes reached nearly one million units per year.

•Launched new programs including supervision of suppliers & vendors, and interfacing with product engineering, quality, tooling, production and maintenance as part of the APQP process.

•Developed proposals, including cost justification, for capital projects, as well as product changes.

•Utilized Microsoft Project, Excel, Word, AutoCAD and Outlook to create budgets then document and track all issues, costs, and timing. Reduced install schedule from 6 weeks to 4 weeks.

•Created and maintained process flow diagrams, work cell layouts, FMEA’s, work standards and operators instructions, all developed with special consideration for ergonomics, safety, error proofing, quality, production efficiency, and to support ISO/QS9000 requirements.

•Worked closely with the GM DRE, and attended program status and design review meetings, to give presentations and discuss issues and timing. Also attended pilot builds at GM truck assembly plants.

•Participating member of three different COMET teams, the company wide continuous improvement and 5S program (Lean Manufacturing) involving shop floor personnel, quality, and Engineering.

FORD MOTOR COMPANY, WINDSOR CASTING PLANT MAY 1987 – AUG 1999

Supplier of engine block, head, and crankshaft castings. (Buy-out, Plant now Closed)

MAINTENANCE SUPERVISOR SEPT 1995 – AUG 1999

Managed PM program and Supervised up to (30) union skilled trades, (3) labour gang, and four clean-up personnel required to maintain (2) molding lines, and the entire melting department.

•Reduced production down time by 20% through PM and efficient troubleshooting.

PROJECT / PLANT ENGINEER DEC 1990 – SEPT 1995

Managed many different projects simultaneously (up to $9.8 mil) from concept through cost estimates, funds justification, design, build, and install, then providing manuals, training, and spare parts set-up.

•Supervised and coordinated activities of Vendors, Contractors, Design Engineers, Maintenance and Production, including drawing approvals, inspection of all equipment and signed-off.

PRODUCTION SUPERVISOR MAY 1989 – DEC 1990

•Supervised up to (30) Union hourly production personnel working on a shell molding line.

PROCESS ENGINEER / INDUSTRIAL ENGINEER MAY 1987 – MAY 1989

EDUCATION & TRAINING

Bachelors of Engineering Science, Mechanical Engineering - May 1987

University of Western Ontario, London, Ontario

Licensed Professional Engineer by APEO, 1990

University of Windsor, Micro-Economics – 1989

GMAT Score – 700 2001

Wichita State University

Macro-Economics - 2001

Business Decision Making & Analysis - 2002

Started MBA program at Virginia Tech, Blacksburg, VA

(8) Courses completed with 3.92 GPA, 2002 thru 2005

Computer Based Decision Support Economics of Business Decisions

Dynamics of Organizational Behavior Production and Operations Management

Management Control Systems Marketing Policy & Strategy

Principles of Finance Accounting Principles

Certified CWB Welding Supervisor & Level 1 Welding Inspector 2011

Safety Training

Part 1 & 2 WSIB Certification for JHSC, 2006

Due Diligence for Managers & Supervisors

St. John’s Standard First Aid with Level C CPR and AED, Nov 2008

Confined Space

Lock-out/Tag-out

Elevated Work / Fall Protection

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