Management 

• Managed Engineering and Maintenance Functions for a seven-facility $1 Billion Meat Producer completing over 130 Capital Projects in just under five years.

• Directed the Maintenance and Capital Budgets for a $1 Billion Food Producer with MRO Budgets of $8 Million per year and Capital Budgets of $5 Million per year

• Planned, Initiated and Completed Capital Projects up to $9 Million in size with extremely tight time frames critical to Production

• In charge of Plant Engineering and Maintenance Management for 350,000 sq ft Pork slaughter facility with a Capital Projects Budget of $3.5 Million, Repair Projects Budget of $1.9 Million, and MRO Budget of $3.8 million.

• In charge of Plant Engineering and Maintenance Management for two potato product processing facilities with $13 MM budget for MRO and Capital Projects

• In charge of Plant Engineering and Maintenance Management for three meat product facilities with $11 MM budget for MRO and Capital Projects.

• Reduction in Plant Maintenance Downtime of 40.37%.

• Reduction of 75% in Engineering Department Maintenance personnel turnover.

• Establish SPC measurement tools and data tracking for downtime.

• Establish budgets for Capital Projects, Repair Maintenance Accounts, Project and Scheduling.

• Establish positive counseling and communication with Engineering Team including Counseling Forms, Progress Records and Measurement Tools.

• Complete planning and budget for reducing maintenance expenses by 10% annually. Goal reached.

• Established a system of Repair Accounts for budgeting major repair expenses on an annual basis.

• Created and implemented Three-year State Certified Maintenance Technical Training Program.

• Completed Tennessee Associates training to become a proficient Total Quality Management Facilitator.

• Train and develop the facility Natural Management Team for the initiation of TQM in the plant processes.

• Planned and directed Contractor Safety Seminar in preparation for Annual Maintenance Shut-Down.

• Implement MUSCLE computerized maintenance system for the facility.

• Implemented MP2 and PSM at various facilities

 

Cost Reduction and Efficiency Initiatives

• Develop line improvement and implement cost reductions on tray pack system resulting in $480,000 savings.

• Completed Carcass Spray System. Shrink reduced from 2.37% to 0.57% creating a yield gain of $3.0 MM.

• Completed Stomach Harvesting Line increasing output from 1,000 to 10,500 lbs per day with minimal labor.

• Completed Bung Harvesting Line increasing output from 500 to 3,250 pounds per day with minimal labor.

• Examined energy/maintenance operating costs. Implemented vendor/contractor changes to reduce costs.

• Established standards for floor reconstruction and re-coating contracts to be implemented with vendors.

• Established facility standards for electrical conduit installation to prevent water related electrical problems.

• Established tracking and record systems for Work Orders and Facility Projects. New systems allowed the plant to assign limited resources to areas needing the largest impact.

• Reduced Plant Mechanical Downtime from 3.75% to rate of 1.89%.

• Reduction of $550,000 in Plant Repair Expenses.

• Reduced Repair and Maintenance Budget spending by $802,537 after three prior years of overspending.

• Reduced Equipment Downtime from 3.25% to 2.066% while simultaneously reducing parts spending.

• Directed energy reduction efforts including capacitors and soft-starts with over $200,000 in annual savings.

• Implemented Maintenance Parts Fabrication / Alternative Vendor initiative resulting in $171,000 in savings.

• Directed installation of Tracer Summit Energy Management System.

• Completed installation of $2.5 MM Auto-Casepack / Auto-Palletize system for four continuous operation wiener lines without any lost production time saving $600,000 annually.

• Created, developed and implemented casings usage tax reduction project saving $700,000 annually.

• Completed installation of circulation/recirculation systems on CWP liquid smoke saving $250,000 annually.

• Design, creation and installation of Main Shipping transfer ramp system resulting in $70,000 labor savings.

 

Environmental

• Completed installation of $1.8 MM, 2 MM gal processed waste water aeration, holding / control tank system.

• Completed improvements for PSM with the Ammonia Refrigeration Systems. Updates included advanced monitoring devices, Enunciator Notification Panel, and new Engine Control Room for refrigeration system monitoring and data collection.

• Completed $0.5 MM Brine energy reduction / environmental containment project saving $25,000 annually.

• Reconfigured outdated Waste water system with SS Vertical DAF and equalization saving $125,000 annually.

• Managed all Environmental Reporting for State and Federal agencies including air, water and waste water.

• Designed and implemented smoke exhaust opacity controls for Alkar Tunnels in discharge reduction project.

• Implement MUSCLE computerized maintenance system for the facility.

 

Projects

• Replaced two Ammonia IQF Flat Product Freezers over a six month period while keeping the other adjacent lines operating

• Consolidated two facilities to take advantage of over $1.5 Million in annual savings

• Completed $3MM Storage Freezer planning and construction project.

• Completed $3.5 MM Automated Product Transfer and Packaging Project in Fully Cooked Sausage

• Completed $8 MM Beef Grinding, Freezing and Packaging Utilization and Upgrade Project

• Completed the design and installation of a new Occupational Health Center for employees.

• Completed research, design and Engineering for 140 / 180 degree hot water heat exchanger system with back-up capabilities to eliminate downtime caused by the loss of 180 degree water in the plant.

• Completed installation of Lactic Acid Sanitizing Cabinets for carcasses.

• Completed installation of the new “Enhanced Pork” production lines.

• Designed and completed roofing over primary product storage areas to eliminate condensation problems.

• Completed Loin Boning and Loin Trimming upgrade project to improve yields and production throughput.

• Completed $2Million, 17,000 sq ft product freezer and 7,000 sq ft refrigerated dock with six shipping doors.

 

Maintenance Management Systems Used

• MUSCLE Maintenance Management System

• GP Mate Maintenance Management System

• Data Stream Maintenance Management System

• PMC for Windows from DPSI and UNIX System Program

• MP2 and Mechanics Mate