Director Operations M&T Manager
RBF Renewable Biofuels
Total years of experience :35 years, 1 Months
RBF operates the largest biodiesel production facility in North America, RBF Port Neches. The RBF Port Neches facility is a BQ9000 accredited facility with a total nameplate refining capacity of 180 million gallons per year.
Spearheaded organizational and facility improvements to increase plant uptime from 63.0% in 2011 to 96.0%, increased plant rates from 15000 MT/month to 36000 MT/Month and developed plan to increase rates to 40000 MT/month.
Executed facility upgrade projects to improve operational reliability and reduce maintenance.
Established site performance objectives and plant operations dashboard.
Staffed up facility to meet business demand.
Expanded logistical capability with installation of 3 truck loading stations
Implemented new process and technology to improve process reliability and product quality100% first time right.
Defined site staffing requirements and recruited and developed plant operations personnel.
Directed establishment of site preventive maintenance program, developed specifications for CMMS program, review systems, purchase and implementation. Implement 5S in the department to improve efficiency and organization Reduced plant maintenance costs by 50% while increasing maintenance department resources.
Established plant maintenance and engineering standards and controls.
Implemented Plant PSM program.
Developed plant safety, quality and production policies.
Developed and implemented contractor selection and review program.
Developed plant budget and established cost controls.
Established site preventive maintenance program, developed specifications for CMMS program, review systems, purchase and implementation of plant maintenance and engineering standards and controls.
Implemented plant safety, quality and production policies.
Established plant operations dashboard and established production objectives.
Developed and implemented contractor selection and review program.
Managed plant budget and established cost controls.
Support development of corporate safety policy.
Arclin is a manufacturer of liquid and powder adhesives primarily used in the wood industry with operations throughout North America.
-Set detailed objectives for all staff personnel and review progress semi-annually.
-Developed production standards for all products. Conduct weekly reviews of performance vs. standards, and when required, create and execute corrective action plans.
-Updated all production procedures and initiated setup of computer-based training system to allow for annual review of operator knowledge.
-North Bay plant named one of top places to work in Northern Ontario. The site had 2 union drives prior to my arrival; I was able to improve overall moral and employee performance
-Implemented program to train 4 operators as 3rd Class engineers by 2011 to fill retirement and backup needs.
-Implemented larger batch sizes (up by 50%), to meet increased customer demand while maintaining existing equipment and staffing. Organization was initially hesitant on implementing batch size increase; however, it was quickly accepted as it freed up more production line time and decreased variability.
-Present plant safety, quality and productivity metrics to all personnel on monthly basis. Discuss any necessary improvements in metrics and provide corrective direction if required.
-Initiated resultant increase in approved funding for 2007 maintenance and capital for the site. Driving the completion of Delta V process control in 2008, and developing plan for plant automation.
-Provide training opportunities for all personnel to improve technical and leadership skill sets.
-Developed annual plant budgets based on sales forecasts and cost escalations. Prepared capital project plan and capital spending forecasts.
-Ensured safe plant operation, utilizing behavioral based safety program. The plant has operated without incidents and has a positive relationship with the regulatory agencies.
Acquired business from Mobil Chemical in 1995 and expanded sales from $350, 000 to $2, 500, 000. Wholly responsibility for all aspects of plant operations including personnel and staff supervision, scheduling, quality control, budgeting, sourcing and purchasing, warehousing, accounts receivable/payable, equipment maintenance, financing, sales and marketing, distribution, safety, government regulations and product development.
Managed acquisition of baby bottle liner business from Presto Products, including purchase capitalization, equipment relocation and customer relations. Successfully relocated production equipment and maintained continuity of supply to new customers.
Consistently maintained plant quality standards, plant always met or surpassed customer audit requirements and product continued to surpass customer expectations.
Negotiated favorable terms with vendors that significantly improved buying power and lowered operational costs. With larger packaging combination orders, vendors holding inventory, and shipping and invoicing as product was released, packaging costs were reduced by 20%.
Initially hired as process engineer, promoted to plant superintendent of plastics plant within 6 months. Wholly responsible for day-to-day operations, including staff supervision and evaluation, safety, quality control, production scheduling, equipment maintenance, engineering, budgeting, capital projects, and product and process development.
Maintained production efficiencies and moral during expansion of sister facility, as new, higher level positions resulted in staff and hourly turnovers. Implemented more structured recruiting and interviewing practices which resulted in a more motivated workforce. Implementation of new technology resulted in increased production with reduced production staffing. Plant became lowest cost producer in the division and as a result we were able to obtain approval for further capital expansion.
Worked closely with sales and marketing team, initiated programs to develop product improvements, including the development of one patent for a new co-extruded stretch film. Close co-operation with division research teams, and strong working relationships with equipment vendors facilitated the implementation of several new technologies which allowed for significant improvements in productivity.
Involved in process optimization of polyethylene plant, troubleshooting and product development. Was able to apply research knowledge to production facility to reduce downtime and improve quality. Involved in technology transfer with sister plants in Texas.Knowledge of copolymer behavior from earlier studies allowed me to work with suppliers to better define material specifications resulting in dramatic decreases in waste production and improved operational costs.Worked with research teams to implement new technology. Initiated capital projects to improve process operation and allow for implementation of new polymerization technology.Lead site engineer on special projects, coordinated site projects with corporate research and engineering groups
Involved in numerous development projects primarily involving polyethylene and polyethylene copolymers. Involved in extensive pilot plant development of catalysts and processes for polymerization of ethylene. Lead team in design and installation of pilot facilities for polymerization and developed reactor for copolymer production. Developed understanding of phase behavior of polymer solution in the production of polyethylene. Developed computer model of phase behavior and worked with production facilities to utilize this information to optimize plant operating window. Involved in thermoplastic composite development, patent was issued in 1989 for this work.