John — Engineer

Revision of AutoCAD drawings

Led converting department producing 200 tonne/day nonwovens. Managed machine recipes, oversaw trials and calibrated equipment. Reinstituted calibration program resulting in 30% fewer downtime events.

Led process improvements for bags, films and roll stock converting. Improved rate, yield and product quality by collaborating with Production using DMAIC tools including DOE, FMEA, MSA and Capability Studies. Drove use of ISRA visual inspection system, ensuring the removal of all holes and visual defects in round-cast film prior to delivery to customer. As a process improvement coach, liaised production process improvement ideas to management, contributing to more qualitative KPIs. Responsible for scoring/cutting for new product development on Preco laser, establishing control and specification limits from results. Authored ASP.NET web-based applications: Process deviation request system for submitting, printing and logging Standard Operation Conditions (SOC) deviation requests, fulfilling ISO requirements for over 100 machines and 500 operators. SOC reporting and compliance auditing system for printing and converting 40 machines at 5 plants. Visual metrics status board providing operators real time indication of progress against schedule.

Led semi-weekly status meetings during major expansion project, updating management on financial and scheduling milestones. Expanded Class 100 clean room for the relocation of production testing lab. Completed Nachi robot training course to facilitate creation and modification of automated material transfer processes.

As pilot plant and laboratory operations manager, managed trials to determine the feasibility of using vacuum distillation for reclamation / purification of products. Managed a vacuum distillation pilot plant facility, including inventory and materials procurement. Scheduled and performed customer-attended trials. Performed preliminary laboratory-scale trials and pilot-scale trials leading to the design, specification and construction of Short-Path and Thin-Film vacuum thermal separation systems for over 15 processing applications. Designed distillation equipment: degassers, flash tanks, condensers, pumps, heaters, vacuum systems and process data acquisition packages. Designed control system for pilot plant equipment and integrated various single loop controllers with Micrologix PLC and WonderWare HMI. Integrated HMI-database-PLC interface program to collect and report SP and PV values to support key customers' production requirements. Audited plant functions and operations to ensure compliance with NEC, NFPA, OSHA, EPA and DOT codes and regulations.

Led Six Sigma Black Belt team in lean techniques to optimize gravure production, reducing raw material waste by 60% for one product line. Implemented process data collection in ISO 9002 certified Gravure department of a $30MM specialty coating and converting facility. Designed production databases, automated process data entry and retrieval and managed equipment installations in ISO 9002 certified $10MM Dry Film Photo Resist plant. Upgraded PLC and DCS data acquisition systems to Y2K compliance on time and 25% under budget. Implemented MS Access databases for WIP testing, data compilation and reports, reducing technician data compilation time by 30%. Supported and improved C++ imaging software used to photograph and store high-speed images of product defects, ensuring quick and accurate response to customer quality inquires.

Selected, installed and commissioned new process and controls equipment for improvements resulting in 40% capacity increase. Managed $3.5 MM capital investment expansion and upgrade projects. Generated P&IDs, PFDs, electrical, mechanical and controls drawings using AutoCAD for fabrication and expansion projects. Managed major project for upgrade from electromechanical to PLC control systems. Commissioned pneumatic blender and multi-station packaging machine. Supervised ISO 9001 compliance program for Maintenance/Engineering department, resulting in on-schedule certification.