Expert Details

Expert in Organoclays, Powder/ Bulk Solids Manufacturing/ Combustible Dust & Process Safety Management/ Continuous Improvement

Expert ID: 733893 Missouri, USA

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Expert spent over 20 years in various roles with a leading global specialty chemical company. As Organoclay Operations Manager he was ultimately responsible for safe and efficient operation of four facilities producing wet and dry process organoclay rheological additives, urethane associative thickeners, and various solvent based additives. Expert's detailed knowledge of Organoclay operations led to him being selected to develop and lead the newly created Process Technology group focusing on strategic process improvement projects, operating cost reductions, and key raw material quality and supply issues impacting future operations.

He initially served in a Process Engineering role responsible for the successful start up and operation of a solvent based, PSM covered, rheological additive production unit.

Expert is a dedicated and self-driven Chemical Engineer with 25 years of experience creating and leading high performance cross functional work teams. Expert has exemplary commitment to Health, Safety, and Environmental excellence. He is an excellent communicator with keen interpersonal skills fostering “buy-in” at all levels. Successful track record of driving continuous improvement through motivation, education, team building, and development. Trained Six Sigma Champion leading numerous capital, operations, quality, and business process improvement projects from conceptual design through project execution. Keen business acumen with ability to balance short term activities with long term strategic objectives. Subject Matter Expert resource for processing, financial, product quality, and technical activities. Respected, trusted, and consistent technical leader with intrinsic ability to create a team environment of enthusiasm and success.

Areas of Expertise: Combustible Dust Management, Batch & Continuous Processing, JD Edwards ERP System, 5S, Process Safety Management, Staff Development & Succession Planning, Capital & Expense Budgeting/ Product Std Costing, KPI's & Visual Factory, Flammable Liquid/ Solid & Toxic Materials, Labor Relations & Contract Negotiation, Variance Analysis & Cost Control, Continuous Improvement (Kaizen) Teams, Trained PHA & PSSR Leader, Procurement & Production Planning (MRP), Process Improvement & Design, Root Cause Analysis, Incident Investigation, ISO 9001 Quality Management, Batch Cycle Time & Yield Improvement, TPM & OEE, Regulatory Compliance & Behavioral Based Safety, Order Fulfillment & Distribution, Project Management, Mistake Proofing (Poka-Yoke).

Expert is a dedicated and self-driven Chemical Engineer with 25 years of experience creating and leading high performance cross functional work teams. Exemplary commitment to Health, Safety, and Environmental excellence. Excellent communicator with keen interpersonal skills fostering “buy-in” at all levels. Successful track record of driving continuous improvement through motivation, education, team building, and development. Trained Six Sigma Champion leading numerous capital, operations, quality, and business process improvement projects from conceptual design through project execution. Keen business acumen with ability to balance short term activities with long term strategic objectives. Subject Matter Expert resource for processing, financial, product quality, and technical activities. Respected, trusted, and consistent technical leader with intrinsic ability to create a team environment of enthusiasm and success.

Retired from the specialty chemicals industry after a thirty-year career in solids/ powder handling operations. Experience includes both hazardous and non- hazardous operations in multiple sites across two different businesses.
Significant materials handled in bulk include:
o Combustible materials
 Bentonite and Hectorite based Organoclays ground to 95% thru 200M and 325 M.
 Various Polyethylene Waxes (pellets and dust)
 Ground PTFE
o Non- combustible materials
 Bentonite and Hectorite Clays (70% thru 200M)
 Synthetic iron oxide pigments
 Zinc Oxide and Magnesium Oxide

Education

Year Degree Subject Institution
Year: 1985 Degree: BS Subject: Chemical Engineering Institution: University of Missouri - Rolla

Work History

Years Employer Title Department Responsibilities
Years: 2011 to 2015 Employer: ELEMENTIS SPECIALTIES Title: Corporate Process Engineering Manager Department: Operations Responsibilities: ∙ Directed raw material study and plant experimental program resulting in $1MM savings by bringing toll manufactured dry process product “in house”.
∙ Led process/equipment studies to identify, then optimize, critical process variables which increased annual dry process capacity by approximately 2,000 MT (33%).
∙ Coordinated technical and operations activities (at Elementis and supplier’s sites) throughout selection, testing, and implementation of an alternate strategic organoclay raw material, creating an annual savings of $500K.
∙ Managed $2MM belt filter press replacement project including process design, equipment testing and selection, procurement, installation, and commissioning.
Years: 2007 to 2011 Employer: ELEMENTIS SPECIALTIES Title: Site Leader Department: Operationsv Responsibilities: ∙ Led operation of the St. Louis site producing 15,000 MT annually with a site budget of $12MM.
• 3,000 MT reacted/ blended flammable products via batch process.
• 12,000 MT combustible dust products via continuous process.
∙ Set direction/goals for HSE, quality, and productivity initiatives.
∙ Developed and executed dry process organoclay expansion strategy through site selection, project execution, and commissioning generating savings over $1MM in toll manufacturing and supply chain costs.
∙ Executed vacuum filter upgrade project at the St. Louis plant on a “fast-track” basis due to deteriorating condition of existing units. Led the team through equipment selection, procurement, construction, installation, and start up leading to a throughput improvement of 10%.
∙ Authored and coordinated an aggressive capital investment plan to rapidly update and modernize the St. Louis site which had been previously planned for closure.
Years: 2003 to 2007 Employer: ELEMENTIS SPECIALTIES Title: NA Organoclay Operations Department: Responsibilities: ∙ Directed HSE, quality, and operations activities at the St. Louis, MO., Charleston, WV., and Newberry Springs, CA. sites. Scope of this role was approx. 50 staff and 150 hourly team members with a financial responsibility of over $30MM.
∙ Managed/prioritized $5-7MM capital investment process for the organoclay sites.
∙ Led the Charleston team resolving simultaneous issues with biological waste water treatment and product dryer performance resulting in a 100% throughput increase.
∙ Directed cross functional Elementis team (HSE, Regulatory, R&D, Procurement, Quality, Operations, Applications) to evaluate and integrate a modified high volume raw material at St. Louis and Charleston plants. Financial impact was $1.5MM raw material savings between the two sites.
∙ Restructured operations team across the sites creating a cost avoidance of $350K.
Years: 2000 to 2003 Employer: ELEMENTIS SPECIALTIES Title: Plant Manager Department: Responsibilities: ∙ Led operation of the St. Louis site producing approx. 12,000 MT annually with a site budget of approx. $10MM. Set site HSE, quality, and productivity goals to maximize contribution to corporate objectives.
∙ Negotiated cost reductions of $500K with Collective Bargaining Unit while maintaining positive relationship.
∙ Implemented Stable Manufacturing program creating 750 MT/year (10%) additional organoclay capacity increase.
∙ Improved maintenance reliability by implementing Preventive Maintenance and 24-hour maintenance coverage.
∙ Served as site Champion for corporate Six Sigma Black Belts creating $100K raw material savings.
∙ Team Member/Operations group subject matter expert for Elementis’ JD Edwards ERP implementation.
Years: 1993 to 2000 Employer: ELEMENTIS SPECIALTIES Title: Operations Manager Department: Responsibilities: ∙ Coordinated all batch and continuous manufacturing operations of the St. Louis site producing approx. 12,000 MT annually with an operations budget of $7-8MM.
∙ Led operating team of six staff and thirty hourly team members.
∙ Achieved immediate step change improvements in manufacturing variances through operator training and motivation improvements.
∙ Optimized organoclay operation resulting in a 500 MT/year (10 %) capacity increase.
∙ Improved efficiency in the UAT polymer process resulting in a capacity increase of 550 MT/year (20%).
Years: 1991 to 1993 Employer: ELEMENTIS SPECIALTIES Title: Process Engineer Department: Responsibilities: ∙ Hired to lead startup of a $4MM solvent based batch production unit expansion ultimately producing over 3,000 MT annually.
∙ Assisted in ISO 9000 Certification for the site.
∙ Managed Statistical Process Control program.

Career Accomplishments

Associations / Societies
American Institute of Chemical Engineers

Fields of Expertise

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