Engineer Project Manager

SENIOR PROJECT/MANUFACTURING ENGINEER

Highly talented and results driven process/project engineer. Proven record of production and process improvements with an emphasis on safety, GMP and cost reduction. Extensive knowledge of material handling equipment, blending and packaging systems, tanks, pumps and piping systems, food grade manufacturing standards and process ventilation systems. Accomplished project manager responsible for complex capital projects with up to $750,000 in spending. Qualified PHA leader. Acknowledged strengths in effective project management, problem solving, communication and documentation skills. Recognized for dynamic, hands on engineering style, positive attitude and strong work ethic with the ability to multi-task and maintain a high level of quality deliverables.

AREAS OF EXPERTISE

• Project Management

• ISO Standards

• PHA Analysis

• Project Documentation

• Grinding Equipment

• Conveying Systems

• Budget Management

• Process Safety

• Process Troubleshooting

• GMP Standards

• OEE Analysis

• BOM Documentation

• Blending Equipment

• Dust Collection Systems

• SPC

• Environmental Safety

• Manufacturing Support

• HACCP

• Management of Change

• PM Documentation

• Packaging Equipment

• Explosion Venting Requirements

PROFESSIONAL EXPERIENCE

FMC BIOPOLYMER, Rockland, ME 1991 – 2010

Food ingredient division of Fortune 500 Company. Manufacturer of Carrageenan (an extract from seaweed). Process includes both wet and dry material handling, various filtration processes, drying/grinding equipment and a complete blending and packaging facility.

Senior Project Engineer 2000 - 2010

Led capital projects from conception. Included design, estimating, detailing, constructing, and implementation at the Rockland Facility. Executed large projects including proposal preparation, project costs containment, coordinating and supervising contractors, engineers and maintenance technicians, preparing project schedules and monitoring project performance.

• Championed a multi-year effort to design an enhanced blending and packaging facility. Resulting design automated all critical tasks, doubled capacity and reduced manpower requirements by 50%. Proposal had a projected savings of over 1 million dollars annually based on an estimated cost of 2.5 million dollars.

• Managed the 3.5 million dollar capital plan for the Rockland Facility. Efforts resulted in annual capital plans that were within 1 to 3 percent of their targets for a period of 3 consecutive years.

• Cited by environmental auditors as an example of ‘Best Practice’ for my work in insuring the proper installation, protection and signage of chemical storage buildings throughout the facility. Reduced material handling requirements by 50%.

• Orchestrated a successful transition from a drum based packaging line to a box based line that reduced packaging costs by 63%. Project included automated and semi-automated equipment to erect, fill, transport and seal the box contents.

• Recognized for project excellence in the development and installation of a process pH control system consisting of a bulk tank, redundant pH measurements and controls as well as pumping and filtering systems. Project resulted in improved Plant performance worth approximately $200,000/yr and another $150,000/yr. in Plant efficiencies. Project was completed below budget and ahead of schedule.

• Led a Plant-wide dust explosion hazard assessment project which resulted in full compliance with OSHA standards.

• Noted by Managers for superior documentation of project files, BOM’s, PM’s and benchmark work orders.

FMC BIOPOLYMER, Rockland, ME

Senior Process Engineer 1991 - 2010

Known by name as the blending, packaging, material handling, dust collection and explosion venting requirements expert throughout the facility. Lead process support for the Plants’ food grade powder applications.

• Received a pay grade promotion in 2002 in recognition of expertise in the grinding, blending and packaging systems.

• Significantly improved the operational performance of the blending and packaging process areas utilizing a team approach to problem solving. Implemented OEE (Overall Equipment Effectiveness) measurements to verify performance.

• Delivered operational efficiency improvements through the following efforts.

o Improved standard grinding rates by 20% utilizing modified process techniques without incurring any capital costs.

o Increased the capacity of the on-line fine grinding process by 25% through operational changes. This significantly reduced the off-line fine grinding requirements to better meet customer order timelines.

o Enhanced the visibility of the Plants’ operational efficiency through the implementation of revised tracking and reporting methods.

o Revised the Change Request System for process and equipment issues. System upgrades increased operator participation by 200%.

o Responsible for completing over 35 Change Requests per year over a ten year period.

• Key dry-end resource for Management and Plant personnel. Effectively resolved equipment and process issues in the grinding, blending and packaging operations.

• Member of the Plant Safety Committee with responsibilities for the assessment and resolution of incident investigations within the facility. Successfully corrected over 60 safety issues during my 12 year term on the committee.

FMC BIOPOLYMER, Rockland, ME

Project Engineer 1991 - 2000

• Eliminated operator exposure and increased system reliability within the waste process stream through the design and installation of a bulk sulfuric acid tank and delivery system.

• Project manager and lead designer/developer for the following efforts:

o Bulk lime addition system that incorporated new conveyor technology and allowed for the stabilizing of the waste stream process and the elimination of ergonomic issues.

o Super sack unloading systems that transferred product from super sacks to totes as well as sift the contents for ultra fine contaminates.

o Saved $15,000 annually through the installation of innovative valve applications that eliminated wear.

o Significantly reduced ergonomic risk by designing a custom test stand for maintenance personnel to validate disc jack functionality.

o Received praise from upper management for achieving noticeable reductions in processing costs by creating a specialty blending area to process small batch orders and test material. Assessed system requirements and quickly resolved issues to deliver process within an aggressive implementation schedule.

R.F. Richards Corporation, Worcester, MA 1989 – 1991

Staff Engineer/Production Manager

Lock manufacturing facility comprised of zinc die casting, metal stamping and assembly operations. Sole responsibility for establishing a statistical process control system within the manufacturing facility. Increased work center throughput by 25% by evaluating, designing and implementing streamlined production processes that reduced production bottlenecks.

Wolverine Corporation, Merrimac, MA 1988 - 1989

Project Engineer

Original Equipment Manufacturer of fluid bed dryers, converorized ovens, coolers and forming equipment for the food processing industry. Responsible for an aggressive research and design project for a Japanese customer to fabricate and deliver a shredded wheat processing line in less than nine months. Coordinated customer specifications with manufacturer’s design concepts. Managed the successful field installation of the equipment and completed operator training in the field.

United States Gypsum Company, Charlestown, MA 1985 - 1988

Plant/Project Engineer

Manufacturer of sheet rock and plaster products. Initiated projects that resulted in increased production capacity, reduced operating and maintenance costs, improved product quality and increased worker safety. Worked with DEP and state agencies to satisfy S.A.R.A.H. and other environmental impact requirements. Obtained multiple dust collector and wharf renovation permits. Responsible for weekend coverage of the maintenance and mill departments.

BASF Systems Corporation, Bedford, MA 1984 - 1985

Associate Quality Control Engineer

Manufacturer of computer tape and disks. Administered a computer tape quality control operation. Investigated quality problems within the computer tape and injection molding operations. Discovered a major tape defect prior to roll-out. Established Q.C. standards and procedures working within a Statistical Process Control format.

Teknor Apex Company, Pawtucket, RI 1980 - 1984

Quality Control Technician (summer intern)

Manufacturer of PVC and rubber compounds. Provided quality control and color matching support for the manufacturing operation.

EDUCATION / PROFESSIONAL DEVELOPMENT

University of Rhode Island 1980 - 1984

Bachelor of Science, Mechanical Engineering

Eagle Scout 1980

Good Manufacturing Practices for the Food Industry, Time Management, Questimate/Microsoft Project, Elements of Applied Process Engineering, FMC Small Project Execution, FMC Project Management and Project Control, Process Hazard Analysis Leader Training, Process Safety Management Training, Mechanical Integrity Training, ASME Code and Pressure Relief Valve Sizing and Selection, Gould’s Pump Sizing and Selection Seminar, Negotiating Skills Seminar, Facilitation & Presentation Skills, Harley-Davidson SOC Certification.

AFFILIATIONS

Cub Scout Leader (2003-2007), Boy Scout Leader (1980-1985, 2007-Present), Wiscasset Recreation Coach of the Year – 2006, Wiscasset Recreation Volunteer Coach (2002-2008), Wiscasset Snowmobile Club Treasurer/Secretary (1994-Present).

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