DAN A by S5n477

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									                                                   DAN A. HAYES
                                                519 Sagewood Drive
                                               Collierville, TN 38017
                                                    901-850-7099
                                              danalanh@bellsouth.net
                                      http://bellsouthpwp2.net/d/a/danalanh/

OBJECTIVE:      To contribute to improvements in the business position of a progressive, growth company through
                advancements in manufacturing, quality and R&D by utilizing my proven leadership, mentoring,
                teaching, technical and problem-solving skills.

SKILLS:         Proven, effective leader with strong fundamental chemical engineering, problem-solving and
                teaching skills. Practical, hands-on, proven track record of accomplishments. Excellent verbal
                and written communication skills with all levels and functions. Able to work as part of a team or
                as an individual contributor. Lean/Six-Sigma methodology. All MS Office software, including
                Front Page, Access and SQL. AspenTech – SQL Plus, Process Explorer, Process Recipe
                Transition Manager. Minitab. Performance Management. Quality Process Facilitation.

EDUCATION: B.S. Chemical Engineering, The University of Akron, Akron, OH - 1986 (GPA: 3.7/4.0). Co-op
           experience with Martin Marietta, Oak Ridge, TN - waste management, fission fuels and fusion
           fuels processing.

EXPERIENCE: 10/06 to Present – AOC, LLC – Unsaturated Polyester and Vinyl Ester Resin Producer
TECHNICAL AREA LEADER (10/06 – Present) – Collierville, TN. Responsible for the leadership of a group of 4
professional and 10 hourly personnel in the areas of process/product engineering and QA/QC/Lab.
 Established a culture of performance measurement, data-based decision making, root cause analysis coupled
    with corrective/preventive action and doing things right the first time, resulting in all-time high customer
    satisfaction and conversion rates and all-time low customer complaint/returns and scrap rates.
 Through use of Six Sigma methodology, debottlenecked vinyl ester manufacturing process resulting in an
    annual savings of $850M.
 Resolved a long-term product color issue resulting in an annual cost savings of $500M.
 Implemented a new product introduction program, increasing customer confidence by eliminating scale up
    errors.
7/86 to 9/06 - Wellman, Inc. – Virgin and Recycle PET Resin and Fiber Producer
TECHNICAL SUPERINTENDENT (10/05 – 9/06) – Bay St. Louis, MS. Responsible for the leadership of a group
of 6 professional and 36 hourly personnel in the areas of process/product engineering, QA/QC/Lab, raw materials
receiving and finished product shipping.
 Coordinated commissioning and startup of a 320 MMlb/yr PET resin expansion.
SENIOR STAFF PROCESS ENGINEER (6/00 – 10/05) – Bay St. Louis, MS. Responsible for process and
product development and production support of a 960MMlb/yr PET resin plant.
 Corporate resource in the areas of melt and solid-state polymerization process and equipment operation, PET
    process design, technical training, problem solving, and practical application of statistical methods and
    information technology in a manufacturing environment.
 Defined and implemented melt-phase and SSP process improvements to increase resin line capacity by
    240MMlbs/yr, increasing annual company profits by more than $24MM.
 Lead Process Engineer for a $50MM, 320MMlb/yr PET resin expansion utilizing idled fiber melt phase
    equipment and new SSP equipment.
 Resolved a company-wide SSP operational problem, resulting in annual savings of $1.1MM and increased
    annual production capacity of 30MMlbs, increasing annual company profits by more than $3MM.
 Developed alternate SSP shutdown procedure, resulting in annual savings of $1.2MM.
 Defined and implemented melt-phase process conditions, including a creative color control technology, to
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    allow production of 1 quality PET staple fiber at 40% of line capacity due to poor market conditions.
 Defined process and equipment and commissioned new process to produce a resin product containing 25%
    post-consumer recycle PET.
DAN A. HAYES

TECHNICAL SUPERINTENDENT (7/97 – 6/00) – Bay St. Louis, MS. Responsible for the leadership of a group of
38 professional and hourly personnel in the process definition, and commissioning of a greenfield 720 MMlb/yr
PET resin and fiber plant in the areas of process/product/project engineering, QA/QC/Lab, environmental, and
training.
 Coordinated commissioning and product introduction of 2 resin lines and 1 fiber line. 1 quality production
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     achieved in 2 weeks or less. Immediate customer acceptance of product.
 Defined all manufacturing and utilities process conditions and customer /product conversions schedules.
 Defined, configured and implemented AspenTech Infoplus.21® manufacturing execution system.
 Specified equipment and procedures to establish the plant QC Lab.
 Defined all quality systems documentation consistent with ISO 9000 standards for later certification.
 Developed training materials for hourly operators. Corporation adopted new format.
 Defined evaluation criteria for the hiring of hourly operators.
STAPLE PROCESSING SUPERINTENDENT (12/95 to 7/97) – Florence, SC. Responsible for the leadership of a
group of 170 professional and hourly operations personnel, in the final production process for polyester staple
fiber. Accountable for department safety, product quality, customer complaints, cost control and profitability and
personnel development.
 Implemented a performance management based safety program that reduced OSHA rates to an all time low
     level of 1.07.
 Implemented a raw material conversion improvement program resulting in a $6.9MM annual cost savings.
 Implemented new automated bale wrapping equipment that resulted in a $1.3MM annual labor savings.
UTILITIES SUPERINTENDENT (12/94 - 12/95) – Florence, SC. Responsible for the leadership of a group of 30
operations and 20 maintenance personnel of the Utilities Department, providing the services of major raw material
handling, wastewater treatment plant operation, environmental operations and general plant utility production and
distribution.
 Defined and implemented a new power distribution switching procedure to allow for overdue maintenance.
 Commissioned a vapor feed from polyester process overheads into the steam boilers and dowtherm heaters
     to thermally oxidize 1,4 dioxane, resulting in a $5MM cost avoidance.
 Transitioned waste treatment plant from parallel to series operation to provide a more robust process for
     changing influent due to plant capacity expansions.
DEVELOPMENT SUPERINTENDENT - New Process Technology (12/91 - 12/94) – Florence, SC. Responsible
for the leadership of a group of six engineers in the definition, justification, commissioning and development of
new technology to reduce process interruptions, process and product variability, and added cost, and for capacity
expansions and environmental remediation projects.
 Defined process and equipment and commissioned new fiber spinning technology, resulting in an annual
     profit increase of $2.4MM and an improvement in product uniformity.
 Defined process and equipment and commissioned new fiber drawing technology that improved product
     uniformity 60%.
 Defined process and commissioned a 525MM lb/yr PET esterification plant, increasing annual company
     profits by more than $50MM.
QUALITY CONTROL SUPERINTENDENT (8/91 - 12/91) – Florence, SC. Responsible for the leadership of one
Lab Chemist, two supervisors and 30 hourly Lab operators in the daily product and process verification and
development testing, continual improvement of Lab test process and cost effectiveness, and coordination of raw
material supplier quality partnerships and improvement programs.
 Initiated efforts and achieved ISO 9002 certification for the Florence Plant.
 Trained Lab operators in the use of and implemented SPC/SQC.
 Obtained certification status with two major raw material suppliers.
PRODUCTION ENGINEER II - Staple Processing (4/90 - 8/91) – Florence, SC. Responsible for addressing day-
to-day process, product and maintenance issues and developing and implementing programs for continual
process, product, personnel and equipment quality improvements.
 Managed $24MM annual department budget via forecasting, variance analysis and cost control.
 Developed VAX/VMS applications to access pertinent operations data from the plant Ingres database.
 Provided leadership for the development of an operator training program that resulted in a $500M annual cost
    reduction.
DAN A. HAYES

PRODUCT DEVELOPMENT ENGINEER II (4/89 - 4/90) – Florence, SC. Responsible for the development,
evaluation and commercialization of processes to produce new products to meet customer demands and strategic
marketing objectives.
 Developed and commercialized a fiber product that increased plant capacity 17%, increasing annual company
    profits by more than $8MM.
 Developed and commercialized a specialty fiber product to replace down insulation increasing annual
    company profits by more than $400M.
 Developed and commercialized a specialty low-pill fiber product, increasing annual company profits by more
    than $3MM.
PROCESS DEVELOPMENT ENGINEER I & II (7/86 - 4/89) – Florence, SC. Responsible for the definition,
justification, commissioning and development of technology to reduce process interruptions, process and product
variability and added cost.
 Defined and implemented esterification process changes that reduced spinning interruptions 30%, resulting in
     an annual savings of $380M.
 Implemented new glycol recovery unit column operating procedures that resulted in a $30M cost avoidance.
 Developed several VAX/VMS, FORTRAN, SAS and BASIC computer programs for data acquisition and
     analysis and process modeling.

References available on request.

								
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