Shaw Industries, Inc Work Values

Daily Duties at Shaw Industries, Inc:

• People Provided leadership, mentoring, knowledge sharing, and coaching for junior engineers, operators, and maintenance in manufacturing operations. Training done in troubleshooting manufacturing processes; verifying liquid and viscous fluid pump and piping sizing calculations, mass and energy balance calculations, energy auditing, and procedures improvements, boiler inspections process; Set up FMGlobal knowledge base for younger engineers including articles on boiler and pressure vessel inspections, loss prevention articles; Water treatment service for over 20 plants; Environmental remediation and Process Safety Management. • Innovation Generated, documented and executed plans to select and/or develop technology improvements in order to meet the specific objectives. Identified areas for improvement in safety, cost, waste reduction, and Overall Equipment Effectiveness. Stack Gas Economizer and Dyehouse Hot Water Distribution System. Installed $334K Recovered heat from boiler stacks, added heat exchanger. Saved $163K/yr. Steam Dryer Automated Condensate Recovery System. Installed $376K Redesigned Steam Coil Dryer Condensate System for 90 steam coils, eliminating off quality wet goods. Saved $484K/yr. • Growth Demonstrated ability to influence people who are not direct reports. Supervised outside water treatment suppliers, improved employee and supplier motivation and performance by developing JDS job redesign. • Strategy Chemical engineering SME leader for cross functional teams for cost out projects. Communicated effectively the status of the work to stakeholders. Performed auditing and feasibility studies, liaison with corporate sourcing, corporate energy, corporate risk management, plant engineers. EPA Boiler MACT Energy Assessment Team Identified energy improvements opportunities by plant saving 1 -5 % wasted fuel; Pipe, Valves, and Fittings Sourcing Team Wrote performance standards, improved capital project piping installation by 25 %, parts delivery time by 75 %, service efficiency by 200 %; Effluent Remediation feasibility studies, redesigned multiple plant capital project installations avoiding costly fines; Title V and CERMS Compliance and Procedures avoiding costly fines. • Capital Project Management Developed Detailed Specifications, RFQ and documents for design, installation, and performance operation of equipment AutoCAD installation drawings, Scope of Work, Project cost estimates, and project schedule documents. Developed documentation and trained personnel on new processes, materials and equipment. • Improved Carpet Waste Burning Boiler and Ash Handling Operating Procedures. Developed trial for ash viscosity control / dilution systems. Reduced unplanned boiler ash related outrages by 75 %, Improved uptime by 10 %; Developed Rotary Drum Vacuum Filter project. Selected technology; installed successful pilot plant; and assisted on scale up project installation team. Project cost $1.4MM. Reduced waste shipment costs by $400K/yr. Developed Equipment EH&S / Operating Procedures. Waste Carpet Shredding for Fuel Source; Boiler Ash Disposal; Boiler Title V Environmental Monitoring; Boiler Dry Storage Procedures. Kiln Controller Calibration. $25K project for temperature and humidity measurement improvements and Honeywell factory authorized training. Eliminated 75 % quality rejects from wet wood. • Multi-plant and departments Technical Support Chemical Engineering SME for many levels including daily production/maintenance, plant technical and management resources, corporate engineering, R & D, and logistics. Provided chemical engineering support for plant engineers on chemical storage and handling, pumps, piping, blending and mixing, steam and condensate handling, energy recovery for boilers, corrosion, water treatment, and emulsion breaking. • Cross Functional Team Chemical Engineering SME on cross functional teams for cost out projects, changes, or reduction in operational costs. Worked with Lean and Six Sigma managers to identify causal factors, root causes, and ranking FMEA process failure types on Severity, Occurrence and Detection, then conducted engineering follow-ups to recommendations. Improved steam utilization in dyehouses. Developed and implemented lab to line correlations on steam demand, quality and steam system mechanical changes for dyehouses. Saved 95% of dye losses. Redesigned space dye steam supplies, reduced dye losses by 20%. Dyeing Steam System Redesign Team. Set standards for improved boiler operation of steam purity/quality, set operating parameters for steamer internal distribution, improved company dyeing repeatability and off quality reductions. Dye and Scrap Waste Reduction. Developed and implemented first liquid UV VIS Spectrophotometer. Reduced scrap from matching tank adds by 90%, and improved production turnover. Developed and implemented improved Reflectance Spectrophotometer system. Reduced confirming strike matching runs by 76%. Supply Chain Management Cost Reductions Teams. Developed and implemented performance-based screening and selection criteria for dyes and chemicals, allowing consolidation and bulk storage of dye house chemicals. $4MM/yr savings. Improved water treatment supplier management program. Worked with water treatment supplier reps to provide process engineering improvements and troubleshooting services to their programs. Sustained level of improvements gained across the company. Reduced fuel losses by $8MM/yr. Instacolor and SST Process Improvements Teams. Evaluated and suggested mechanical, electrical, PID and controls programming changes to Instacolors automated dye and chemical mixing systems for 7 Shaw plants. Reduced dye delivery variation rates 50-75%. Reduced FMEA Severity and Detection risk. Improved JDS employee motivation and performance. Batch Mixing Improvements Teams. Evaluated over 100 mixing tanks and provided modeling calculations to improve shearing, and blending performance at 7 plants. Improved batch mixing reproducibility between plants by 25%. Inhouse Chemical Plant Project Team. Member of design team for initial facility cost $550K. Saved $2MM/yr

What they like about Shaw Industries, Inc:

You give high priority to hiring firms with prestige. Market reputation and prestige of a firm may be determined through on-line research, and conversations with individuals working in your target industry. Note that firms "in the public eye" receive a great deal more critical publicity and attention than those operating with more anonymity. So as you assess your employment opportunities, be sure to seek out the positive aspects of the firm's reputation in addition to noting negative publicity the company may have received.

Tags

Troubleshooting, Process Engineering, Mentoring, Chemical Engineering, Energy, Mixing, AutoCAD, Visio, Coach and Support, People, Innovation, Growth, Build Customer Satisfaction, Subject Matter Expert, Water Treatment, Steam and Condensate, Energy Recovery, Environmental, Safety, Cross-Functional Teams, Maintenance Best Practices, Six Sigma, Lean Manufacturing, Batch Mixing, Continuous Mixing

Skills

Mentoring, Lab Instumentation, AutoCAD, Visio, Allen Bradley PLC Rockwell Software RS Tune and RS Logix, Microsoft Office Suite, FLOWTRAN, ASPEN Process Simulation, Process Measurements , SME Water Treatment, Energy Optimization, Knowledge of fluid mechanics, Chemical Engineering, Process Engineering, Coaching and Supporting, Batch Mixing, Continuous Mixing, Environmental Remediation , Process Safety Management, Process Redesign, Procedures

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