DAN A. HAYES 519 Sagewood Drive Collierville, TN 38017 901-850-7099 firstname.lastname@example.org 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 st 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 st 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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