Resume - Results-Driven Leader/Senior Executive, BS/MS/PhD work ChE, MBA, PE, 25+ years e...

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Resume #35206

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Senior executive with highly successful record in operations, turnarounds, startups, P&L/project management, strategic planning, & business development.
Results-driven leader adept at capitalizing on opportunities, analyzing needs, solving problems, & managing teams.
* $600+ million/yr savings by eliminating OSHA violations. $200+ million/yr profit by doubling plant capacities.
* $200+ million/ship savings by implementing six sigma/reliability best practices and eliminating 75+% rework.
* $25+ million/yr savings by eliminating 50+% rework in semiconductor facility.
* Directed, managed, constructed, started up, developed, designed, & improved $multibillion production facilities.
* Outstanding communication, technical, & management skills. Managed 80+ person staffs/teams.

EDUCATION
MBA at University of South Carolina, Distinguished Student Award recipient, 3.9 GPA. 1988-91.
PhD work Chemical Engineering at University of California, Berkeley, 3.8 GPA. 1985-87.
MS Chemical Engineering at University of Delaware, 3.5 GPA 1982-83.
BS Chemical Engineering at State University of New York at Buffalo, Outstanding Student Award recipient, 3.9 GPA 1978-82.

EXPERIENCE
Project/Maintenance/ESH Eng. Mgr at NORTHROP GRUMMAN/WESTAR, 2nd largest defense contractor 2003-Present.
Led/directed engineering/reliability/ESH/maintenance/project management for multibillion-dollar composite shipbuilding processes.
* $200+ million/ship savings by eliminating 75% rework. Standardized/improved/developed/implemented: engineering design review & report/human factors/reliability/RAM/system safety/ incident tracking/MRP/operating manual/best practice systems.
* Developed/implemented: engineering (6 sigma/SPC)/safety/reliability/human factor/continuous improvement systems.

Sr. Systems Mgr./Eng. at PRAXAIR SEMICONDUCTORS/SAIC/WORTH, 2nd largest industrial gas firm 2000-2002.
Led engineering/ESH/operations management for semiconductor, aeronautical, $1.4 billion VX, & construction processes.
* $25+ million/yr savings by eliminating 50% rework. Standardized/improved/developed/implemented: MRP/ISO/engineering design review & report/operating manual/best practice systems. Determined chemical compatibility/cycle life/better labeling for system components. Tested/modeled air/z-purge/pipe flow/purge efficiency for cabinets and valve manifold boxes.
* Developed/implemented: design/safety systems, crane/VX PHAs, and JSA/investigation programs (due to 3 fatalities).

Process Engineer/ESH Manager at MILLENNIUM CHEMICALS, 2nd largest pigment producer 1995-99.
Led/developed/implemented/improved six sigma/ESH/operations/best practice management for multiple titanium dioxide pigment production facilities. Evaluated/commissioned capital projects.
* $200+ million/yr profit by doubling plant capacities. Commissioned reactors, conveyers, and spray dryers. Interacted with EPC contractors. Issued capital project feasibility/EVA reports (ore/coke silos, ore blend, CWC, steam/chlorine reduction).
* Used SPC six sigma/TQM/Intrinsic Safety/ERP to improve/troubleshoot daily production activities (Finishing/Chlorination, QA/Lab).
* Increased PSM program compliance from 50% to 100% ($300,000 savings by internally developing programs):
* Conducted/revalidated PHAs/HAZOPs (3000+ action items). Sized relief devices (by modeling release scenarios).
* Developed best practices (titanium tetrachloride release reduction, electrical classification/ventilation for fuels).
* Streamlined/enhanced Management of Change/Pre-Start-Up Safety Review/Emergency Response systems.

Mgmt/ESH Consultant at BOISE CASCADE/AMERICAN TAPE, 2nd largest office supply/paper producer 1993-95.
Led, directed, developed, implemented, evaluated & improved ESH/operational best practice management programs.
* $600 million/yr savings by eliminating OSHA violations (2 months ahead of deadlines) for two pressure-sensitive tape facilities.
* $400,000 savings by internally developing PSM/RMP programs using teams. Increased PSM program compliance from 5% to 100% for the pulp and paper mill (60% ahead of 2.5-year timeline).

Mgmt/Process/ESH/Eng. Consultant at JBF ASSOCIATES, largest risk management consulting firm 1991-93.
Led/managed landmark catastrophic $multimillion capital audits, PHAs, & developed/evaluated/improved ESH/PSM/RMP programs for chemical, paper, petroleum, nuclear, & pharmaceutical industry clients.
* Evaluated/enhanced OSHA-dictated PSM programs at various chemical facilities and paper mills.
* Completed PHAs: petroleum product marine terminal HAZOP, hydrogen utility system FMEA, material transfer process fault/event tree/ human risk assessment. Assessed restart capabilities and developed operational safety requirements for several nuclear facilities.
* Developed environmental RMP offsite consequence assessment methods for A.I.Ch.E./specific industrial clients. Published 2 A.I.Ch.E. PSM issue-related papers, 17 reports, and numerous proposals.

Process Engineer at WESTINGHOUSE/DUPONT, largest chemical producer 1987-91.
Led, directed/managed, developed, & started-up $multibillion production facilities.
* Led/directed startup of the $2.4 billion Defense Waste Processing Facility (DWPF). Interacted with EPC contractors. Simulated Salt Process procedures on DCS. Placed the organic waste storage tank in operational order.
* Managed/directed startup of the $150 million Replacement Tritium Facility (RTF). Interacted with EPC contractors. Directed/installed metal hydride beds (one month ahead of 3-month schedule). Redesigned in-bed nitrogen feed system (a vital tritium accountability component).
* Led/directed construction of $7 million Thermal Cycling Absorption Process for the Tritium Production Facility. Communication catalyst: Voluntarily relocated to the production area to keep project going (due to a production personnel shortage). Redirected project plans and scope (increased process scale, redesigned "leaky" aluminum column to stainless steel) to be relevant to RTF's and production's needs. Completed construction turnover. Transferred responsibilities back to production.
* Managed operation of the Advanced Hydride Laboratory, the RTF's $4 million pilot plant. Discovered leaky nitrogen valves and recommended tighter-sealing valves for the RTF ($3 million cost savings). Implemented/ evaluated/documented metal hydride tests/results. Programmed process control system.

Process Design/Development Engineer at ALAMEDA INSTRUMENTS, semiconductor startup firm 1987.
Led/designed novel sulfuric acid and hydrofluoric acid reprocessors for semiconductor industry clients.

Process Development Engineer at CELANESE, largest methanol & 2nd largest fibers producer 1984-85.
Led/managed economic feasibility studies for new/improved chemical production processes. Used process simulation software to support the economic evaluations:
* Investigated using methanol as diesel fuel. Proved coal-processing costs made methanol uneconomical.
* Developed reactive distillation software package. Tested package (for ethylene glycol/polyol production).
* Produced economical Ibuprofen production comparisons for various reaction/feedstock scenarios.

Industrial Intern (M.Ch.E. Thesis) at GLAXO SMITHKLINE, large pharmaceutical/specialty chemical manufacturer 1982-83.
Led/managed a process development study for a new pharmaceutical product (market value: $0.5 million/lb):
* Enhanced membrane fractionation between the product & an excess reactant by selectively binding the product with polymers.
* Developed a thermodynamic model to quantify the product-polymer binding interactions.
* Analyzed experimental results using high-performance liquid chromatography (HPLC) & freeze-drying.

Development Engineer at W.R. GRACE Summer 1982.
Quality Assurance Engineer at DUPONT Summer 1981.

PROFESSIONAL ACTIVITIES
American Institute of Chemical Engineers (A.I.Ch.E.).
American Society of Safety Engineers (ASSE). Former CSP/OHST.
Registered Professional Engineer (P.E.) in Michigan and Ohio.
Advanced Toastmaster/Competent Leader/District PR/President/Area Governor.
Top Secret Security Clearance.

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