Snyder, Texas, United States
Leading the plant’s mechanical integrity and reliability program for process equipment assets to meet regulatory compliance Minimizing process risk at the site by proactively seeking solutions and conducting routine field audits for HSE and PSM Working closely with contractors and maintenance lead for prioritization of work orders, PMs, trainings & site improvements Developing capital plan for site with the team and manage CAPEX projects for plant upgradation Lead MOC process, PSSR, continuous improvement to cut down processing cost by utilizing lean manufacturing tools
Optimizing RC inspection process by applying lean techniques to make it continuous from batch. Assisted in installing new columns utility, ozone, nitrogen and heat exhaust lines along with batch feed tank. Processing the permit paperwork for an incoming 1000 gallons blended solvent tank for facility expansion project. Standardizing the RCs fittings for DNA expansion project for the ease of filling blends with faster rate without product failure. Designed 2 dedicated RC filling stands, 50% more efficient in filling with pressure sensors to stop filling at pressure buildup. Ordered and in process of designing frame for pneumatic pail crimping tool for leak free pails delivery to the customers. In process of installing new nitrogen heater for activating adsorption and absorption columns along with waste heat nitrogen recovery. Currently working for a distillation operation forerun collection drum scale to collect data for different batches to avoid waste. Finalizing the contractor for proper lining and guideways for warehouse and manufacturing building. Updating, scanning and keeping up with facility equipment PMs. Ordering backup parts and inventory balance.
Successfully completed lean six sigma yellow belt certification for process optimization to reduce waste. Launched new standard operating procedures and work instructions as per quality management system. Solved and initiated process CARS, CAPAS to cut down product failure rate internally by implementing proper corrective actions. Machining of new anodized aluminum chucks for better gripping and efficient capping without breaking the bottle caps. Conducted internal audit for different departments to improve and prepare better for any outside, customer and regular ISO audits. Designed tables for mounting gripping base to hold smaller bottles to be capped using pneumatic torque wrenches instead of manually by universal torque to avoid any potential leak, spill and safety hazard situation. Trained new and existing relevant department employee on newly released, existing updated work instructions & SOPs to keep up with higher production efficiency getting work done right at the first time.
Solving day to day reactors, receiving tanks and manufacturing problems related to Honeywell Automation system HC-900, tank level sensing issues, pneumatic air controls of reactor transducers & solenoids, Honeywell pressure & temperature transmitters, equipment calibration, process controls and reactor room investigations in case of near miss or any incident on site. Controlling any unplanned reactors, automation system, pump repairs and fill stands downtime. Calculating the emissions generated during solvents manufacturing on monthly, quarterly and yearly basis for reactors, receiving tanks, overhead condensers, blending tanks, mixer and submit it in timeline manner on Ohio EPA portal electronically. Calculation for Fee Emission, Permit Evaluation report annually with renewing reactors air permits every 5 years. Taking over Recycletainer leadership to keep production in a continuous RC filling operation by maintaining supply chain from RC scheduling to its inspection as per DOT standards and regulations. Recycletainer projects including optimization & process mapping, repair cost sheet, ordering quality parts while keeping up with the inventory, preparing capital expenditure requests for upcoming new projects, customer special requests for RC configurations, steam cleaning, pressure drop, leakage and particulate issues. Completing RC related complaints, issues and CARs by finding the root cause, preventive actions, helping customers by providing technical assistance to keep their continuous production flow. Designing of fill stand pneumatic air control boxes on demand for our sister company. Accomplished multiple fill stand projects includes designing of 6 new fill stands, 2 acid fill stands along with fill stand dedication project to reduce human error, contamination issue and eliminating re-sampling problem makes overall process economically efficient.
Treating 7000 plus gallons of industrial wastewater generated daily from the mechanical finishing of tier-3 aerospace, automotive & OEM supplier parts (12 million parts per month) that undergoes through different finishing processes include vibratory deburring, barrel finishing, tumble blasting, shot blasting, rust removal & prevention, descaling, centrifugal disc cleaning, parts cleaning & washing and citric passivation Monitoring and training employees on work instructions for ISO-9001-2008 for improving process & product quality Calculation of chemical addition with engineering calculations & formulation for treating the wastewater based on the finishing process with maintaining daily record of chemicals used Perform all aspects of sampling, monitoring, analyzing & testing required to maintain compliance with Federal state & Local Regulations governing the wastewater treatment process, treated water quality and sludge management Setup a lab for testing the quality and concentration (in ppm) of Zinc in treated wastewater with equipment calibration Preparation and implementation of presentations for treated wastewater plan & corrective actions by attending local Compliance Attainment meetings with metropolitan sewer department of Cincinnati Familiarity with FMEA, APQP, PPAP, Root Cause Analysis, Lean Manufacturing, 5S, Corrective Actions on processes & customer complaints Training operators on the floor for process improvement, equipment reliability, environmental health & safety hazards Currently working on introducing a new process of Black Oxide coatings from scratch on automotive parts for the huge profitability, further growth of the company with least capital investment & engineering economics strategies in the same facility Present continuous improvement plan to vice president with new multiple startup projects including chemicals cost reduction, process optimization for high productivity, recycling, business development & regeneration of used chemicals
Maintaining the water chemistry for the equipment including boilers, cooling towers, chillers, water softeners, makeup-up water tanks, condensate return water by calculating conductivity, hardness, checking pH, chlorides, sulfites, alkalinity of the water Line tracing of equipment with fault detection, servicing, maintaining and troubleshooting process problems with proper records Calculation of boiler and compressor duty with new proposed sizing of boilers, cooling towers, process parameters to ensure more efficiency and utilization of steam energy loosing for the overall process of heating & ventilation operation specially in winter time Maintain water quality standard in efficient way in collaboration with maintenance and water utilities department Equipment cleaning, descaling and chemical addition for ensuring smooth process was conducted
Marketing of specialty chemical sales, engineering applications by meeting customers demand with an efficient processes and savings cost per annum for wastewater, cooling water treatment, boilers water chemicals, food grade grease, anti-rust chemicals, defoamers, industrial lubricants etc. Visit industries as per requirement for the process evaluation to check and maintain water chemistry for boilers, cooling towers, softeners and feed water tanks. Prepare and deliver technical presentations for explanation of the existing products and cost savings.