Sr. Construction Manager

Project Director

Project Manager responsible for all aspects of a new $1.2B State of the Art Thick Slab Steelmaking complex.
The project will include a 180T DC EAF, RH Degasser, Twin Station LMF, Twin Station LTS, Bulk Alloys and Iron Substitute Addition Systems as well as a 1.8MM Ton Thick Slab Caster (first Greenfield Thick slab caster in the US in 40 years).
Project also include all new utilities (including Statcom) and a port facility.
Managed the EPCM Contractor (40+ staff) and the Owner\’s Project Team (8 staff).
Reported out to various JV Steering Committees (Safety, Schedule, Budget, Risk and other project Metrics)
Led the implementation of the Risk Register and led all Root Cause Investigations.
Managed major OEM relationships (Primetals, Sarralle, Morgan Crane and others)

Engineering Manager- Project Palmer

Manager of Engineering for a new State of the Art $750MM Rail Rolling Mill. Mill is the first Greenfield facility in the US to both roll 100m long rails; and weld those sections into lengths up to 400m.
Responsible for Value Engineering the project and reducing the Project Budget by over $150MM.
Led the effort for all Engineering aspects; this including OEM Engineering, the external Engineer of Record and the Owner\’s team Engineering. This included all Engineering disciplines: Civil, Structural, MEP, Automation and Safety systems.
Managed all aspects of the Major OEM Contracts (Danieli, Holland. Linsinger, Kuenz and others); approved all Factory Acceptance Tests.
Managed 6 person Engineering Staff and the external EOR

Corporate Director Of Facilities and Maintenance

Responsible for all Kimber Manufacturing Equipment and Facility Maintenance and Reliability performance. Lead CapEx funding activities for all major projects.
Current manufacturing footprint include 5 operating units (on 4 campuses) in NY, NJ and AL. I am also the Project Manager for the new State of the Art Mixed use facility in Troy, AL. This project includes Manufacturing, R&D, Additive Manufacturing and Office Space (~$45MM Project).
Existing Facilities: 3 direct reports with 30 total staff. Total campus size of ~400k square feet of Firearms Manufacturing (CNC Machining, Finishing, Heat Treatment, Test Range and final assembly operations).
New Troy Facility: 3 direct reports, with 10 total staff. This campus will be ~250k square feet; with an additional outdoor test range (2 indoor ranges) and land for future expansion.
Implemented new MRO Storage plans reducing MRO Inventory and Warehouses by 25%.
Worked with Operations Management to design, layout and install all new Production and R&D works cells at the Troy, AL facility.
Implemented the plan to move all CNC machines from NY area to Troy, AL.

Engineering and Facilities Manager

Engineering & Facilities Manager: (2/2016 to 12/2018) Responsible for the company\’s Capital Expenditure Program (annual, 3 & 5 year planning); also lead all major projects (> $1MM).

Upgraded the CapEx process to more accurately reflect project execution risk and cost basis; standardized CapEx requests and provided new project estimating templates. Driving a culture of continuous improvement in the Project Management & Engineering functions.
Responsible for all Plant Engineering functions / Supervise team of Design and Process Engineers
–Reduced Capital Project Carryover by 90%;
–Reduced Capital Project overrun by 80%.

Outsourced most plant facility maintenance activities, reduced department manpower & costs by 70% and greatly improved customer service

Major Capital Projects personally managed:
-Warehouse Optimization Project ($3MM): Installation of modern magnet cranes + Building Structure upgrade. Reducing non value added processes, increasing safety.
-Upgrade / replacement of all Rolling Mill DC Drives ($2MM): 40,000hp of ABB DCS800
-Caster Turret Replacement: $500k
-Negotiated new Demand Response Power agreement (BPA); $3MM cost savings

Continuous Improvement Projects:
–Safety PLC System with remote control of circuit breakers
–Multiple Energy Audits & projects (industrial LED lighting, waste gas heat, energy efficiency, etc)
–Electronic Relays and Metering including:
SEL-751A (Arc Flash Sensors); SEL 735 (w/ Synchrophasors); RTAC-3530 w/5045 TEAM Software;

Implemented a new Electrical Safe Work policy including upgrading all Arc Flash protection systems (Fiber Optic sensors, Maintenance Mode settings, etc).

Expanded the existing Predictive Maintenance and Reliability Centered Maintenance programs by implementing the following:
–Enhanced Transformer Oil Sampling
–Compressed Air Auditing, Monitoring and increased preventive maintenance
–Partial Discharge and Ultrasonic Electrical Cable & Switchgear testing

Project Manager / Engineering Manager

Project Manager: (4/2013 to 10/2014) Project manager for a $60MM Brownfield Aluminum Cold Mill expansion and upgrade project. Project consisted of upgrading and converting an existing 2 Stand Tandem Cold Mill to a 3 stand cold mill. Including new controls (power systems, automation and drives), new hydraulics (HAGC ), new Coolant House/Filters and new Environmental controls.
In addition to the upgrades listed a 3rd Mill stand was added to the Tandem Mill arrangement (Stand 3); creating a new 3 Stand Tandem Mill from the existing 2 Stand mill.
In addition to the Cold Mill, a used Edge Trim slitter was purchased, and upgraded to further process the Aluminum Sheet. Upgrades included new controls, hydraulics, mandrels, strip lubrication and coil transportation.

Engineering Manager-Total Maintenance Center (TMC): 10/2013-10/2014. Responsible for all Engineering functions for TMC. TMC\’s 3 main lines of business were as a machine shop (precision machining of parts), maintenance and field service operations and outside Engineering and Project Management solutions. Directed and mentored a team of Direct Reports (14 Engineers and other professionals) on a day-to-day basis. Developed a culture of continuous improvement and value engineering.
Responsible for all Engineering Costs and outside revenue generation. Reported to the President of TMC.

Served as the Corporation\’s Technical lead (COO led the overall team) in discussions with various 3rd parties for the supply of Automotive Aluminum Sheet. Worked closely with all C-Level management to negotiate contracts (investment, technical/Intellectual Property, commercial, etc.) with multiple international and domestic partners.

Led the effort to launch a new Contractor safety qualification/training program, with an annual refresher training requirement.

Project Director

Project Director for a $100MM Greenfield project in China (Changzhou, Jiangsu Province). Project is the first dedicated Body in White (BiW) Aluminum facility in China (Continuous Annealing and Solution Heat Treatment-CASH + Chemical coating). In addition this project is the first facility in China for Novelis.
Developed the project from the concept stage, while working with the corporate strategy team. Developed all Project Budgets, Detailed Feasibility Studies (DFS), Business Cases and Organizational structure for the new Wholly Owned Foreign Enterprise (WOFE). Reviewed and obtained Project Approvals from the Global Capital Committee.
Performed due diligence on site and vendor selection. Negotiated contracts with International equipment vendors, Consultants, Local (PRC) Engineering / Design Institutes and Local (PRC & Provincial) government agencies / industrial parks.
Interview local and international team members to staff the project.
Controlled all aspects of the project to meet schedule and budget requirements.

Manufacturing Excellence:
Actively engaged in plant appearance standards, focusing on standardizing the Novelis Brand across our operations in 4 Continents. To support this initiative, I developed and authored the Plant Lighting Standards to standardize all indoor lighting throughout the corporation.
Led the effort to standardize purchasing and repair specifications for all power transformers (oil and dry/resin core).
Act as internal consultant on Power Distribution and Electrical safety challenges.

Project Leader for large ($550MM) Cold Rolling complex project in Germany. Provide leadership while working with the strategy group to define the project from concept to funding requests. This included all stages of planning (FEL-1 to FEL-3) and FEL-4/FEED studies. Worked closely with the Corporate Strategy group to perform detailed review of various business opportunities (business case development and review).

Project Engineer

Project Engineer in the Central Engineering group. Lead / manage capital and major maintenance projects. Act as the technical lead for the plant\’s electrical power system.

Electrical Supervisor

Meltshop & Caster Area Electrical Supervisor. Responsibilities include the safe and reliable maintenance of the plants power distribution system, Electric Arc Furnace (80MVA with inline Reactor; both equipped with online Tap Changers), Ladle Met. Furnace (20MVA), Vacuum Tank Degasser and 3 Strand Continuous Caster. Responsible for the safety, development and leadership of 5 Engineers and 11 Electrical Technicians and the promotion of the plant\’s overall safety and business culture.

Rolling Mill Electrical Supervisor. Responsibilities include the project management and engineering of the 550K/tpy SBQ bar mill. Managed all startup activities for the Rolling Mill and Finishing Area facility. This included the engineering, design and purchase of over 600 motors, 150 VFDs and 25 MCCs, ranging in size from 6000hp to fractional hp motors. Drive Systems included MV VSI drives (TM-70), common DC bus drives (Active Front End (AFE) and Regenerative Front End drives).

Level 1 & Level 2 Automation and controls systems. Systems consisted of Rockwell ControlLogix PLC systems, Wonderware InTouch HMI and a custom Level 2 (Manufacturing Execution System).

Responsible for the safety, development and leadership of 2 engineers and 9 electrical technicians.

Project Engineer / Construction Manager

Various Industrial Capital Projects, these include:
JHBP Plant # 10, new plant construction and installation in Pulaski, VA. an aproximately $105MM project.
Project Engineer for all Electrical equipment and systems. This included a new 138kV substation, various power distribution equipment, Variable Speed AC and DC drives (including a 2000hp DC Drive).
Construction Manager for West Coast facilities. Projects included a New Linea Line and Warehouse Project, Reno, NV. Aproximate budget $25MM. Negotiate contracts for Engineering Services, Civil Construction, Mechanical and Electrical Installation.

Took a leadership role in the corporate electrical safety, standards and reliability.

Process Control Engineer

Responsible for the mill\’s Level 2 Automation System / Manufacturing Execution Systems (MES). This including all servers, applications and databases. This system was one of the first Windows based MES systems deployed in the Steel industry (vs DEC / OpenVMS systems). Supervised and mentored various more junior Automation Engineers. Served the Database Administrator (DBA) for the Oracle RDBMS.

Designed, developed and implemented the plants power distribution SCADA system; including the load sheding / power demand control system. Successfully started up the Alstrom Static Var Compensator (SVC).
During the construction phase I took over leadership of the Construction and Commissioning of the Continuous Caster and Lade Met Furnace (LMF) areas.

In addition led the effort to construction of the 2 main office buildings (2 story tilt up construction; approximately 100,000 square feed under roof). Project included the company Data Centers, nurse / first aid stations and all parking and landscaping.