Engineer Safety

Jefferson Neil Thornton

*********.********@*****.***

PROFESSIONAL SUMMARY

Chemical Engineer recognized for achievements in R&D, Safety and Environmental projects, with 25 years in Safety, Health and Environmental, aerospace materials and processes, research and development, chemicals, design, analysis, and hazardous waste. Licensed Professional Engineer skilled in technical problem solving, environmental and safety regulatory compliance, process development, design of experiments, hazards analysis, computers, and risk assessment. Dependable, productive, thorough, positive, and innovative engineer and leader who makes sound technical decisions.

QUALIFICATIONS AND SKILLS

• Professional Engineer license

• Experienced PSM process hazard analyst

• 11+ yrs process safety analysis/assessments

• FMEA, HAZOP, PHA, JSA, JSO, FTA

• Root Cause Analysis, Mishap Investigation

• SPC, Lean manufacturing, TQM, SMS

• Sound decision maker with positive style

• 29 CFR OSHA standards, 40 CFR EPA

• Innovative solutions, DOE and reduced costs

• Chemical Engineering BS degree BYU

• Materials and process engineering experience

• Project management of concurrent projects

• Excel, Word, PowerPoint, Statistica, Fortran

• Chemical product and process optimization

• Write methods, technical reports, presentations

• Flexible; gets along with others; teamwork

• Tool design, structural analysis, CAD, integration

• Strong ethics, industrious US citizen, dependable

ENGINEERING EXPERIENCE

BAE Systems Casper, Wyoming

Chemical Engineer Less Lethal Research and Development 2011 to Present

Managed R&D chemical lab. Designed and developed pyrotechnics for fuze, chemical munitions, and flash bang products used by law enforcement, military, corrections and government agencies. Developed innovative solutions for several concurrent projects attaining product performance objectives while coordinating product and process safety, environmental impact and permits, lean manufacturing, and DOT hazard classification. Prepared test plans, mixed chemicals, built products, design test experiments and data acquisition, conducted statistical analysis, wrote test reports, and presented R&D milepost findings of Preliminary Design, Detailed Design, Engineering Pilot, and transition to Manufacturing take-over.

• Achieved technical, safety, integrated schedule, and cost objectives of prioritized projects.

• Made critical assessments of problems and designed experiments leading to innovative solutions.

• Created new products and intellectual property. Mentored and supported Engineering and Production areas.

ATK Launch Systems Brigham City, Utah

Research Engineer/Scientist V R&D, Propellants and Pyrotechnics 2000 to 2010

Conducted research and experiments for contracted technology programs for military customers. Developed designs, evaluated and correlated data, applied scientific and engineering principles, evaluated proposals, and managed technical projects for materials and processes of solid propellants. Increased efficiency, reduced costs, developed safe solutions, and solve technical problems. Created innovative designs and test plans with limited budgets. Evaluated ingredient properties, compatibilities, and effects. Analyzed explosive mix properties, ballistics, and cured mechanical properties. Prepared detailed reports of findings and technical solutions.

• Conducted propellant development and supported manufacture mix and cast of 300,000-lb rocket motors

• Achieved technical, design, safety, integrated schedule, and cost objectives of prioritized projects.

• Made critical assessments of problems and designed experiments leading to innovative solutions.

• Developed product and process technology and authored technical disclosures, procedures, and reports.

• Resolved manufacturing concerns by designing subscale simulation of critical process parameters.

• Specified details for experiments and propellant scale-up. Analyzed data and reported results.

• Investigated changes to material and processes, mix and cast process parameters, and propellant properties.

• Developed methods, set up tests and managed details, analyzed data, and developed correlations.

• Formulated reusable non-curing inert propellant for mix and cast process checkouts. Met AHOPS guidelines.

• Prepared technical reports and presentations; e.g., met NASA request to analyze inadvertent ignition at KSC.

• Developed inert simulant for full scale remote process checkout prior to use with energetic propellant.

Thiokol/Alcoa Brigham City, Utah

Principal Engineer - Safety Space Operations, Industrial Safety 1992 to 2000

Provided Space Shuttle Industrial Safety leadership for process hazard analysis and risk assessment projects. Managed process safety management activities emphasizing process safety analysis and safety engineering. Championed workplace health and safety compliance. Applied knowledge of safety administration and safety engineering. Developed, evaluated, communicated, and implemented hazard control methods. Interpreted and applied assessment data to develop and improve control strategies. Analyzed designs for materials, processes, and facilities to minimize potential OSHA risks and meet customer needs. Applied company health and safety guidelines, ergonomics, hazardous operation standards, industrial hygiene controls, and regulations to lead consistent program of OSHA compliance and risk reduction. Investigate mishap incidents, determine root cause, and provide corrective action. Provided safety training. Worked effectively on teams to analyze process safety and control and minimize identified risks.

• Conducted hazards analysis: PHA, FMEA, FMECA, PFMEA, JSA, HAZOP, PrHA, O&SHA, FTA, PRA

• Area of my safety responsibility achieved over 11 years (1.4 million man-hours) without lost time injury

• Planned, budgeted, scheduled, and executed hazards analysis assignments for process safety management.

• Presented safety concerns and risk assessment findings to review boards and area safety committees.

• Conducted structural analysis for tool designs. Modeled explosion, fire, and chemical scenarios.

• Managed safe test operations, reviewed planning, issued flame permits, and conducted inspections.

• Analyzed buckling capability tests of instrumented RSRM case (Team Recognition).

• Analyzed RSRM rocket motor static test stand refurbishment with thrust capability (Team Recognition).

• Led process hazards analysis and fault tree analysis of twin screw extruder mishap (Solid Contributor).

Thiokol Brigham City, Utah

M&P Design Engineer R&D, Propellant Materials and Processes 1989 to 1992

Designed and conducted R&D scale missile propellant test plans for Navy Trident missile program. Created designs, developed procedures and planning, prepared memos and reports. Solved problems involving raw materials and explosives, grinding and weigh-up, mixing and casting, cure and mold release, propellant ballistics, rheology, and mechanical properties. Reviewed proposals and responsibly maintained Earned Value Management System budgets. Managed mix and cast projects from inception to detailed execution, testing, data analysis, and reporting. Accountable for EVMS.

• Designed propellant casting assemblies and made over 300 five-gallon mixes of nitrate ester propellant.

• Authored mix procedures and lab technical procedures for energetic material processes and testing.

• Conducted job safety analysis/observations. Designed tests and conducted cure and mold release studies.

• Estimated and monitored schedules and budgets for managing propellant mix, cast, and test projects.

Morton Thiokol Brigham City, Utah

Engineer/Analyst - Safety Lab and Test Operations / Hazards Analysis 1987 to 1989

Applied investigative and analytical tools to ensure safe manufacture and testing of DoD missile programs and NASA Space Shuttle rocket motors and systems. Analyzed near miss and catastrophic mishaps. Implemented safety management systems. Perform process hazard analysis projects; e.g., FMEA, HAZOP, Fault Tree Analysis, PrHA, O&SHA, What If, Probabilistic Risk, and Blast/Fragment Analysis with Criticality Analysis and closed loop actions.

• Coordinated hazards analysis projects with manufacturing, operations, maintenance, and facilities.

• Analyzed design, process, system integration, and procedures for equipment, tooling, facilities, and tests.

• Determined hazardous event consequences of fire and explosions using manual and computer models.

• Verified closure for safety actions identified using SMS, PHA, and risk assessments.

US Pollution Control, Inc. Grassy Mountain Facility Tooele, Utah

Environmental Process Engineer Hazardous Waste Treatment/Disposal 1986 to 1987

Tested diverse incoming waste samples including blended chemicals, acids, caustics, flammables, oils, and nerve agent. Treated and disposed of hazardous wastes in compliance with RCRA and TSCA regulations. Inspected site tanks, piping, landfills, secondary containment, and monitoring wells. Provided comprehensive safety training and monitored compliance. Installed pump systems to collect and monitor amounts of leached chemical wastes at landfill. Collected soil and ground water samples. Periodically tested fire protection systems.

• Tested hazardous waste samples to analyze chemical and physical properties of manifested waste.

• Kept detailed records of waste disposal, land treatment pumping project, and leachate detection.

• Trained site personnel, distributed personal protective equipment, and conducted site inspections.

• Collected water and soil samples per permit and monitored environmental impact on ground water.

• Treated wastes with high sulfide/cyanide content prior to neutralization, solidification, and landfill.

• Maintained fire protection equipment including tanks, pumps, hydrants, hoses, and extinguishers.

• Operated heavy equipment tractor, loader, track hoe and bobcat during waste disposal operations.

EDUCATION

• CHEMICAL ENGINEERING Brigham Young University, Provo, UT 1986

• Bachelor of Science Degree with minors in Math, Chemistry, and Spanish

PROFESSIONAL TRAINING

• Professional Engineer (Utah)

• Safety Professional (BCSP)

• Secret Clearance (DoD)

• First Responder CPR

• Process Safety Management

• Design of Experiments

• Technical Writing (Shipley)

• Explosives and Propellants

• DoD 4145 Quantity Distance

• Pyrotechnic Formulations

• Presentations, Control Boards

• AHOPS Compliance, PPCB

• ISO 9001, Quality Management

• Statistical Process Control

• Six Sigma, Lean Manufacturing

• Process Hazards Analysis

• Toyota Production System

• Kaizen, JIT, 5S

• 29 CFR 1910 OSHA Standards

• Fault Tree Analysis

• Minitab, Statistica, PHA Works

• Excel, Word, PowerPoint

• Fortran, C, Pinnacle, Modeling

• SolidWorks, I-DEAS, CAD

• Blueprints, Drawings, Specs

• Tool Design, Stress Analysis

• Ergonomics, Manual Lifting

• NFPA and NEC Guidelines

• Hazardous Waste Operations

• 40 CFR EPA Regulations

• RCRA, TSCA, CERCLA

• Management Principles

• Lab Technical Procedures

• Electronic Shop Instruction

• Fault Tree, PFMEA, FMEA

• Spills, Whazan, Degadis

• SMS, JSA, PHAWorks

• MathCAD, ChemCAD

• NASA-Lewis CEA

• Crucial Conversations

• Coach, Referee, Instructor

• 49 CFR HAZMAT

Contact this candidate