Resume - A highly effective Chemical Engineering Professional who meets challenges head-o...

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Resume #88087

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PROFESSIONAL PROFILE

A highly effective Chemical Engineering Professional who meets challenges head-on and creates positive change. A creative and detail-oriented Six Sigma Black Belt, with a proven record of success in new product development and process improvement; and track record of success developing and leading teams to optimize plant resources and design and develop highly profitable, and innovative products.

BACKGROUND SUMMARY
More than twenty-five years of chemical engineering and plant operations experience includes:

Process Improvement DFSS/MAIC Process Modeling
Process R&D Experimental Design Process Control Programming
Process Research Multi-Site Operations Plant Design
Six Sigma Black Belt Pilot Scale Development Project Costing / ROI
Process Troubleshooting Plant Automation Quality Assurance Programs
Cycle Time Reduction Plant Technical Support Product Development

EMPLOYMENT HISTORY

Dow Chemical, Midland, Michigan and Freeport, Texas 1986 - 2009
Natural Oil Polyol Project DFSS Black Belt, Freeport, Texas (2007 - 2009)
* Worked as DFSS (Design For Six Sigma) black belt for a key full-scale build project to make polyols from soybean oil. Used key DFSS tools to determine the needs of customers and the business, and driving those needs into the new process design. Developed a detailed economic analysis to assist in project evaluation and determining optimum site alternatives.
* Combined three existing models in an established business to develop a complex economic analysis comparing company's asset configuration and operating philosophy with that of the competition. Results showed that changing market demands had resulted in higher company operating costs. Implementing changes will create a projected savings of $20MM per year.

Process R&D Sr. Researcher - Water Soluble Polymers, Midland, Michigan (2002 - 2007)
* Developed a new product for the high-growth, high profit HPMC capsule industry, using a combination of lab scale experiments and modeling. Assisted in plant scale-up, with product performing as predicted. Solved a key customer performance problem and developed a new test method to control and maintain high performance. Over $40MM in new business growth in under two years.
* Led team efforts to reduce insoluble fiber levels in HPMC products. Led team to find root causes of fibers and developed a novel process to make extremely low fiber product in the pilot plant. Patent application pending.
* Optimized a new low-viscosity process, which suffered from a loss of key personnel and process knowledge, resulting in poor quality product. Mentored and trained new engineers and operators to understand key product control parameters and how to maintain them, optimized control of key factors that improved product quality. Wrote training manual to maintain process knowledge and established regular communications to maintain new high product quality levels needed for new business growth.

Six Sigma Black Belt Project Leader - Water Soluble Polymers, Midland, Michigan (2000 - 2002)
* Led a Six Sigma black belt project team to improve HPMC washing for low-viscosity feedstock, in anticipation of future customer needs. Results led to wash improvement with minimum capital, utilizing existing equipment in multiple manufacturing sites with higher quality, and enabled development of new and successful, highly profitable products.

Research Engineer – METHOCEL, Midland, Michigan (1994 - 2000)
* Solved a long-term quality problem for a 50% profit-margin low-viscosity HPMC business. Reviewing past research reports and new lab experimentation led to discovery of reactor alloy incompatibility, previously considered unimportant. Coated entire reactor/agitator with Teflon-loaded epoxy coating, reducing quality rejection by 80%. Prevented imminent loss of business profits, which then grew from $10MM to $20MM in 2 years.
* Designed a new low-viscosity process based on continuous improvement work regarding methods to eliminate two quality issues preventing product growth. Trade secrets and patents resulted from research. Built new $15MM process, which allowed product entry into new HPMC (hydroxypropyl methylcellulose, a water soluble polymer) capsule and capsule coating businesses. Business grew from $20MM to $100MM over next several years (50% profit margin).

Process Control Engineer and Lead Solids Handling Engineer - DRYTECH superabsorbent polymers
Midland, Michigan (1990 - 1994)
* Programmed, simulated, debugged and started up a large, successful superabsorbent polymer heat treat process. Optimized new superabsorbent polymer dense phase transfer processes. Fines inventory reduced from several million pounds to zero in two years.

Production Engineer - Diphenyl Oxide; DOWFAX surfactant Midland, Michigan (1986 - 1990)
* Optimized an o-phenylphenyl process (DPO plant). Improved OPP purity capability index from 0.5 to 10.

Owens-Corning Fiberglas, Amarillo, Texas; Valparaiso, Indiana 1983 - 1986
Plant and Quality Assurance Engineer
* Developed one of the first computer-based process control charts in the company. Designed and implemented a Lotus 123 spreadsheet and "macros" to track and managed binder solids in the fiberglass production process. The approach resolved a long-standing quality issue, and dramatically improved product quality, consistency and output.
* Conducted an extensive root-cause analysis of process inconsistencies for glass fiber manufacturing. Identified several contributing factors including furnace design, ambient temperature, and processing temperatures at various points in the process.

EDUCATION: BS, Chemical Engineering
Purdue University, West Lafayette, Indiana

OTHER TRAINING: Six Sigma Black Belt: Dow Certtified

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