Engineer Manager
Resume:
Oswaldo Hazbón
Allen, TX, 75013 **********@*******.***
SUMMARY
Energetic Bilingual Chemical Engineer with a background in North & Latin American operations and a broad experience in Engineering Management, Projects, Safety, Quality Control & Quality Assurance (ISO-9000 /14000 Programs), Six Sigma, and Process Control Engineering. Skilled in leadership, innovation, data analysis and problem solving.
Expertise includes:
• Process & Equipment Design.
• Design Layout of equipment
• Process Improvement & Optimization
• Capital & Operations Budget
• Product & Process Development
• Continuous/Batch Operations
• Technology Transfer
• Statistical Process Control
• Project & Process Management
• International Tolling Operations
• HazOp Analysis
• Problem solving analytical skills – (Troubleshooting)
• Carbon Black Technology
• ISO Programs Internal Quality Auditor
• Data Critical Analysis collected during site visits (Auditor Skills)
• Process Flow Analysis (PFD’s P&ID’s)
• Cost Management
• Technical Sales
• Inventory Management
• Packaging & Raw Materials Evaluation
• Quality Assurance
• EH&S Programs
• Plant Star-up, New Products run test.
• Creative with great common sense, focused in Objectives and establishing priorities
KEY ACCOMPLISHMENTS
• Chosen one of “The 10 Most Successful Colombian Production Managers” Manager Magazine, Vol. #32, May 2000, Colombia. Implemented procedures to obtain the ISO 9000 and ISO 14000 certification for Cabot Colombia plant, increasing sales by 30MM lbs/year in Europe and Asia.
• Awarded “Cabot Latin-American Reinforcement Operation Team Award 2000". As a Chairman of the Latin American Production Managers team (Brazil, Venezuela, Argentina, Colombia and Mexico), process variables were optimized in the reactor chamber, heat exchanger in the air combustion areas; production rate (yield) of the least efficient product (Vulcan 6) was improved, achieving 27% increase with financial benefits of $ 2.8MM/yr in each plant, an annual business impact of $14MM.
• Designed, built, installed and started up an automatic additives system for the Cabot Pelletization department. After 6 months from start-up, it was standardized for all Cabot Latin America plants, generating savings in raw materials and operation costs of $350K/yr in 5 plants, with total savings of $1.75MM in the region with an investment of $743K.
• Successfully refitted line for new product that rapidly opened new regional market within five months. Earned yield savings of $900K/yr by completing a $2.2MM capital installation. Reduced raw materials costs by $300K/yr, improved quality and increased overall equipment life 12 years by leading and coordinating several interrelated capital projects, i.e. new reactor reaction chamber, new insulation materials, new nozzles design for the raw material injection in the reactors, and new design of tail gas exits from the reactor to the heat exchanger.
• Led a great team effort with Shipping, Quality Control, and R&D departments recovering 1MM lbs of off-quality finished goods (OQ) in 9 months. The value of the recovery after sales was $5MM. Awarded the “Cabot Colombia Quality Award 1997”.
• Led Packaging and Utilities areas in the process of ISO-9001 and ISO-14000 certification for the Polystyrene plant (Styron*). Successfully obtained the certification in record time (7 months). In same year, 1993, awarded “Environmental, Health and Safety (EH&S)”, after working 915 days without accidents.
• Converted a powder ribbon blender mixer into a mixer for granulated products. Conversion was done in 9 days (equipment test, process development and production acceptance), complying with DowElanco product launch date. R&D approved the product, which had reported gains of $4MM in the first year, with a $70K investment. Awarded the “Dow Colombia Production Special Recognition Award, 1989”
PROFESSIONAL EXPERIENCE
CARBONYX Inc. Plano, TX, 04/2008 – 11/11/2011.
Engineering Services Manager
Managed the Process Engineering (production and utilities) in order to build 3 new mega-plants with a production capacity per year of 1million tons of final product (per plant). One project in India and two in USA, which are based in a innovate technology. Using coal (coke) as raw material and after several critical reactions in a controlled environment, the resulting product is a semi-crystalline carbon structure that has applications in the iron, steel, and mineral processing industries as a clean alternative energy source. It has been developed for industrial environments as a coke replacement, with zero environmental impact.
• In charge of Process Engineering Calculation, Equipment Design, sizing and vendor selection process for 3 new project plants.
• Created the full sets of PFD’s and P&ID’s (350 drawings/set), 28 Operation Manuals, and 19 Training Manuals to be applied after the commissioning alongside the operation team of our customers, the plant owners.
• Coordinated team effort with different Engineering disciplines (Mechanical, Electrical, Civil, and Electronic) to arrange on-time delivery of 100% of the task required by the different projects.
SANTA REGINA INTERNATIONAL S.A. Palmer, TX, 04/2005 – 10/15/2007
Production Manager 11/2006 – 10/2007
Managed the day to day operations of two fully automatic Engineered Terrazzo Tile and Countertop production lines (18K SqFt / day) with the collaboration of a team of 2 Production and Quality Control Supervisors, 18 Operators, 1 Process Engineer and 1 Foreman Supervisor.
• Prepared and accomplished the annual Production Budget ($ 1.8 MM) and controlled production costs.
• Completed 23 Capital Projects (equipment and facilities), with an investment of $ 1.07MM, where 9 projects were identified in the CIP process generating $204K in annual savings with an investment of $323K.
• Responsible for Production Planning and Product Quality Control Process.
• Accomplished the Annual Plant Maintenance Program ($480K), Security Programs and EH&S programs.
Senior Process Engineer 04/2005 – 11/2006
Utilized Process Engineering for production and utilities and supported Customer Service.
• Started-up production processes of two new automatic production lines (Mixing and Polishing).
• Improved curing process time from 24 hr/batch to 18 hr/batch, generating savings of 38% in production cost and increasing annual capacity of the plant by 35%.
• Improved the final polishing step, reducing the residence timing into the polishing machine by 19% per batch, generating savings of 335K per year, in “Head Diamonds” (the most expense item in spare parts maintenance).
• Reviewed the Engineering detail on Piping Instrumentation and Diagrams (PI&D’s), and all the Process Flow Diagram (PFD) with the Italian technician’s representative from the vendor company using the HAZOP Program (Hazardous Operation Program).
• Created and implemented the Production Manuals for two lines (Mixing and polishing) and 18 jobs descriptions for every position in the plant, as well as the Global Manufacturing Procedures (GMP) and the Standard Operations Procedures (SOP) for the specific technology.
• Created and implemented Safety and Security programs applying the respective standards for the Engineering Stone process. Evaluated costs for the new product formulation (Custom formulations).
CABOT Colombia S.A. Cartagena, Colombia. 06/1997 - 01/2001
Production Manager
Managed daily operations of two Carbon Black production trains (400,000 lbs/day), leading a team of 9 Production and Q.C. Supervisors, 21 Production Operators, 2 Project Engineer, 2 Process Engineer and 1 Senior Principal Supervisor.
• Created and accomplished annual Production Budget including raw material cost ($ 6.8 MM), control of the Production Costs. Production Planning, Product Quality Control Process, Annual Plant Maintenance Program, Security, EH&S and Quality Assurance Programs (ISO Certification).
• Implemented 38 Capital Projects (equipment and New Formulation process), with investment of $2.7 MM, where 6 projects were identified in the CIP process generating $804K annual savings with investment of $1.7MM.
• Evaluated new raw and packaging materials options, working with suppliers such as ECOPETROL’s Cartagena Refinery, saving $2.7MM/yr.
• Investigated new product formulations working alongside the Cabot Tech Center in Boston, USA and led development/optimization for new products and processes.
Senior Process Engineer Cartagena, Colombia. 02/1996 - 06/1997
Led the Process Engineering of production and utilities.
• Reviewed and kept the GMP, SOP and any modifications and/or technical process changes in the ISO-9000 manuals up to date.
• Responsible for equipment, PLC and instrumentation troubleshooting, the designing of new process and capital projects, detail engineering, pilot plant process development alongside the tech center, scheduling of plant shutdown and start up, TQC and SPC, plant personnel training, analysis of process data, and synthesis of the data into innovative plans and solutions.
DOW CHEMICAL Cartagena, Colombia
Senior Process Engineer
Polyestirene Plant (Styron*) and Utilities Facilities 2/1993 – 9/1995
Accountable for daily technical support and troubleshooting, root cause analysis in the operation of two Polystyrene production trains, one with HDPS and the other with LDPS (400,000 Lbs/day). Supporting programmed maintenance and emergency shutdowns and start-ups.
• Implemented 17 Capital Projects (Production equipment, packaging and Utilities ), with an investment of $2.2 MM, where 3 projects were identified in the CIP process generating $608K in annual savings with an investment of $235K and other project were about improvement of packaging rate (Yield), achieving a 19% capacity increase in their area (11,500 ton/year). This investment was only $123K used in a total of 3 months.
• Led the team of Packaging and Utilities areas in the process of ISO-9001 and ISO-14000 certification for the Polystyrene plant (Styron).
• Coordinated trained personnel in manufacturing, packaging and warehouse departments on the new technologies, new products, new raw materials, and new packaging materials.
• Managed the Polystyrene Utilities Department activities, worked on projects, cost savings programs, new developments and ensured the 100% reliability and Quality support on supply for the following systems: External Power, Emergency Power, Natural Gas, Nitrogen, Water Potable, Water process, air, Heat, etc.
• Served as stand-in for the Production Manager during absences.
DOW CHEMICAL Cartagena, Colombia. 09/1991 - 02/1993
Engineering Department Senior Supervisor.
Managed and implemented Capital Projects and Improvement Department for the Cartagena Site and external support for the Venezuela and Brazil sites.
• Reported to the Cartagena Site General Manager with an annual budget of $6.8MM.
• Exercised basic administrative responsibilities to evaluate nine multidisciplinary Engineers’ potential and professional interest to design their career path accordingly.
• Prepared and managed annual Department budget based upon capital project needs in each facility and production requirements for the Colombia, Venezuela and Brazil facilities, with an average per year of 235 projects, 4 with budget of $2.2MM and the others with budget between the range of 100K and 500K.
• Managed technical resources to give Engineering support to 6 production facilities (Herbicides, Insecticides, Polystyrene, Polyols, Incinerator, Maritime Terminal, Bulk Storage Terminal), reviewed and defined scopes and estimates, provided detail engineering and coordinated construction, and installation of capital and expense projects.
• To Coordinate activities, resources and training personnel to ensure that every Engineer of the team be an expert in management of the LABA System Training for Engineers (Latin America Betterments and Additions), as well as ensuring that every Engineer attends the “Capital Project Management” course in the Tech Center located in Brazil.
DOW CHEMICAL / DOWELANCO Cartagena, Colombia. 02/1989 - 09/1991
Latin America Tolling Operation Supervisor ( LATOS)
Reported to the DowElanco Agrichemicals Cartagena Site Manager with an annual budget of $ 1MM. The LATOS position principal responsibilities consisted of the daily monitoring and management of the total production process in the 12 different facilities localized throughout Central and South America in 9 countries such as Colombia (3), Venezuela (2), Brazil (1), Argentina (2), Peru (1), Costa Rica (1), Guatemala (1), Nicaragua (1), and Honduras (1).
• Among these were Plant Development, Operation Procedures in bulk lines, Filling Machine Test, Legal Contracts, QC Protocol, Production Planning and Inventory Control.
• Implemented and monitored Industrial Hygiene program (particularly the daily analysis of Cholinesterase Hormone in the Insecticides area operators), Security program, Reactivity Chemical program and Environmental control program in production and packaging areas, similar to the programs in the Cartagena site in Colombia. These were conducted in order to have the same production philosophy and standards in every tolling plant as those of a DowElanco plant.
• Implemented Quality Control Program.
• Approved the distribution of the final products.
• Prepared the production forecast plan (Active Ingredient), Raw Material and packaging material, Labels, production in the Cartagena site plants, in order to feed the external sites (Tolling Operations) for their production needs.
Agrochemical Production Engineer
Managed the production operations of two Agrochemicals production facilities (Herbicides and Insecticides), with a production capacity of 7.5MM and 2.5MM lbs/year respectively. Supervised and developed a team of 4 Production and Q.C. Supervisors, 18 Production Operators, 10 filling lines operators and 1 Senior Principal Supervisor.
• Implemented and monitored of Industrial Hygiene program, especially the daily analysis of Cholinesterase Hormone in the Insecticides area operators, Security Program, Reactivity Chemical program and Environmental control program in production and packaging areas.
• Managed the daily operation of the plant, empowered the team to develop, present and support data driven decisions using several skills like Six Sigma, Production Efficiency, Statistical Process Control methodologies, Lean Manufacturing Operations, OSHA Regulations & Requirements, Total Quality Management (TQM), Advanced Quality Planning (AQP), Microsoft Project, Emergency Response Training, etc.
ADDITIONAL EXPERIENCE
Professor
College professor in the School of Chemical Engineering and Food Chemistry in The San Buenaventura University. Professor on the subjects: "Heat Transfer II” on the Chemical Engineering Department and “Unit Operations II” on Food Chemistry Department. These subjects are given in the last year of the Chemical Engineering major’s bachelor degree.
English Literacy/Civics Education Program – GED Teacher
Lewisville and Carrollton-Farmers Branch ISD, Carrollton, TX, 09/2002 - 02/2004 Lewisville, TX, 01/2004 - 03/2005.
In charge of the entire GED program, from the placement survey which analyzed the level of each student, followed by identification of the Individual Diagnostic Profile and specific needs for each student, to preparation of the material for the required subject. The five subjects covered by this program were Mathematics (Arithmetic, Algebra, and Geometry), Science, Social Studies, Geography, and English. Greatest achievement was graduating 127 people with a GED (High School) Diploma.
Production Manager
PURINA- LANZA S.A., Bucaramanga, Colombia. 10/1984 – 02/1989 Designs, Construction, Start-up and Production Management.
Student Co-op Program
Worked in Dow Chemical TS&D as a Co-op. Evaluated several formulas for a market of a new product based on PS with Saran as oxygen barrier for food applications, as well as in plastic oxidation in DCS calorimetric stabilization.
EDUCATION
Studies in Master’s Degree in Food Chemistry.
Industrial University of Santander. Bucaramanga, Colombia. 1986 GPA 3.50 /4.0
(Not graduated)
Bachelor's Degree in Chemical Engineering
Industrial University of Santander. Bucaramanga, Colombia. 1984 GPA 3.63 / 4.0
PROFESSIONAL DEVELOPMENT
• Scientific Investigation Methodology
• Operations Management
• Dupont Line Supervisors with Audit Training
• Project Management Pro
• Air Conditioning and Refrigeration
• Heating and Ventilation
• Ethics
• Negotiating to Yes
• Performance Based Management
• Team Technology
• Styrene Polymers Training
• Time Management.
• Performance Based Management
• Statistical Process Control
• Capital Project Management
• DCS-3000 Operation & Instrumentation
• Carbon Black Technology
• ISO-9002 Module I - II – III
• Internal Quality Auditor ISO-9000 & ISO-14000
• Process Management
• Styrene Polymers Training
Contact this candidate