Senior Reliability Engineer
963 Woody Hill Circle
Evans, GA. 30809
Tel. (706) 664-9341 email firstname.lastname@example.org
Summary of Qualifications:
Facility Maintenance, Reliability Engineer with extensive background in manufacturing machinery and facility maintenance, mechanical and electrical project management, utilities management, predictive, preventive maintenance, and machinery lubrication. Focused on improving plant safety, equipment reliability, reducing energy usage, increasing maintenance skills, performance, and utilization.
B.S. in Industrial Engineering New Jersey Institute of Technology – 1981
A.A.S in HVAC&R technology Somerset County College -1979
Reliability engineering, Machinery Lubrication Specialist, Vibration, Infrared, Ultrasonics, Hoisting & Rigging, Fall protection, and prevention, Arc Flash/ Electrical hazards, CPM (Certified Project Manager), TPM (Total Productive Manufacturing), Six Sigma Green Belt, Lean Culture, and tools.
Reliability Engineer – Senior Mechanical Reliability Engineer Novelis Aluminum
Greensboro, GA (2015 to Present)
• Responsible for all reliability related activities at an Aluminum refining facility converting recycled aluminum into cast ingots.
• Introduced Predictive maintenance programs to the facility and employees. (Infrared thermography, Vibration monitoring and analysis, Ultrasonic for mechanical and leak detection, Oil and Lube monitoring and analysis).
• Optimizing existing PM’s and Work procedures. Creating new PM’s and eliminating non value added PM’s. Changed the format of the PM’s to add sections for technician feedback and recording conditions / measurements.
• Troubleshooting operations equipment to reduce downtime on worst performing equipment.
• Equipment guarding subject matter expert. Replacing, modifying guarding to enable employees to clean and service equipment during operating time.
• Increased the use and effectiveness of work order system. Created equipment criticality / work order prioritization system.
Asset Care Manager, Reliability Leader Georgia Pacific
Warrenton, GA (2013 to 2015)
• Responsible for all Maintenance and Reliability at a 40-year-old, 110MM board foot / year lumber mill that included all processes from Log processing, Chip N Saw, Kiln drying, Planer and Shipping.
• Managed a Maintenance / Reliability dept. of 19 mechanics, electricians, reliability techs,
• Responsible for annual maintenance operating budget of $2.5MM.
• Worked with Warrenton team to increase annual mill output from 77MM to 110MM board feet in 18 months.
• Improved the skills and training of maintenance employees with lubrication, alignment, mechanical drives training for mechanics and PLC, AC drives training for electricians.
• Introduced / increased the use of Infrared thermography, Ultrasonics, Vibration monitoring, Laser alignment and Oil analysis by maintenance and reliability employees.
• Implemented work order planning, scheduling, and parts kitting to increase maintenance efficiency.
• Used work order backlog, equipment criticality ranking, operations input to plan and schedule maintenance and contractor efforts for daily and weekend maintenance efforts.
• Led efforts to review and revise equipment PM’s to increase effectiveness and drive PM generated work.
• Led efforts to increase hourly employee ownership of operating equipment by pairing Maintenance and Operations employees during PM’s, breakdowns. Resulted in more involvement and equipment knowledge by both groups.
• Managed and increased the use of RCFA / 5 Why techniques to reduce downtime and repeat failures.
• Worked with corporate project engineer to plan and execute three major capital projects to increase mill output.
• Responsible for entire mill fall prevention / protection program training and application.
Facilities Maintenance Engineer Covidien Medical
Augusta, GA (2012 to 2013)
• Responsible for facility maintenance and providing all plant utilities, services at a 280,000 ft2 Wound care products facility.
• Owner of the CMMS system (Maximo), Improving PM performance and value, use of failure codes for root cause definition, tracking of labor and materials involved with maintaining equipment.
• Responsible for Supply room, cost reduction, identifying critical spares, adjusting inventory levels.
• Introduction of predictive maintenance equipment and techniques including Infrared thermography, Vibration monitoring, Ultrasonic leak detection.
• Improved efficiency of Boilers, Chillers, Cooling towers.
• Implemented an equipment criticality rankings and critical spares assessment program.
• Managed Contract maintenance providers (HVAC, Grounds, Janitorial, Security, Pest control).
Plant Engineer Shaw Industries
Thomson, GA (2005 to 2012)
• Responsible for maintenance and providing all required plant utilities and services at a 400,000 ft2 carpet fiber production facility producing 100 million lbs. of yarn annually.
• Manage 12 Electrical, 11 Mechanical, 2 Computer, 1 PdM, 1 Purchasing, and 9 Janitorial employees.
• Designed and implemented a comprehensive Predictive Maintenance Program (PdM) using Infrared thermography, Ultrasonic, Vibration, and Oil analysis that other Shaw Industries plants based their programs on.
• Implemented a lubrication program for the entire plant that included employee training. Designed and built a central storage and dispensing system, added filtration, level control, and lubrication ID tags to all plant equipment. This program was adopted as a standard for other Shaw plants.
• Developed a detailed PM program for HVAC units, Cooling Towers, Air compressors, and Dryers that used pictures, diagrams, measurements, specifications. Previous program was very generic.
• Organized a plant wide Equipment Critically ranking system to help set work order priorities.
• Developed, installed, and started a first of its kind 2MW 4,200-volt electric boiler with Georgia Power, Cleaver Brooks, Gaumer Process, Electric Power Research Institute.
• Air compressor controls and monitoring – Lowered plant compressed air set point from 165 to 135. Installed two distinct systems with controls to tie all compressors together. Reduced compressor power cost by $140M annually. Instituted a comprehensive compressed air leak reduction program. Installed airflow measurement, monitoring, and recording, power measurement, CFM/kW measurement.
• HVAC and Chiller controls- Enthalpy control system that monitored outside air temperature and humidity to reduce chiller usage by using outside air to cool the plant.
• Lighting Upgrade – replaced over 1,600 fixtures in the facility with energy saving T-8 Fluorescent. Received Federal and State rebates for energy reduction.
Project Manager Federal Mogul
Summerton, SC (2004 to 2005)
• Directed all work for new product introduction, on GM, Ford, and Chrysler Gaskets, Seals, and Engine Assemblies from design through manufacturing and introduction into customer plants.
• Responsible for the development, installation and start up of a $1.3 million highly automated assembly cell for production of GM Gen IV engine front cover, producing 7,000 assemblies / day with complete error proofing and product tracking.
Senior Project / Equipment Reliability Engineer Wellman Inc.
Darlington, SC (1999–2004), Johnsonville, SC (1997–99), Marion Plant, Marion, SC (1994-97)
• Directed a six-person maintenance reliability team dedicated to improving equipment performance, increasing yield, reducing downtime, and reducing waste and parts spending.
• Directed a $550M complete overhaul of a 300-ton, dual line fiber baler to reduce stops and downtime.
• Upgraded 16 bale strapping and positioning systems, added accuracy, repeatability and lowered costs. Reduced strap breaking by 38% and saved $171,000 per year though reduced parts usage and costs on strapping, stretch wrapping, and packaging equipment.
• Initiated and managed a project to automate polymer extrusion screen changers, resulting in maintenance cost, labor, and material savings of $600M.
• Upgraded a 40-PSI waste steam header to a 75-PSI process steam header that used waste steam in dryers offsetting the use of virgin 300 PSI. Saved $280M per year.
Capital Project Engineer Sybron Chemicals Inc.
Birmingham, New Jersey and Wellford, SC (1990 – 1994)
Maintenance Manager and Project Engineer Johnson Matthey Inc.
Wayne PA (1985 – 1990)
Maintenance Supervisor United States Steel
Fairless Hills PA (1981 – 1985)
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