Romeo Urbinelli

R​OMEO​ R. U​RBINELLI 103 Maple Trace, Rincon, Georgia ∙ - ∙- EDUCATION: Bachelor’s of Science in Mechanical Engineering, ​December 1997 Pennsylvania State University, U ​ niversity Park, Pennsylvania Completed the following MBA level coursework, M ​ arch 2003 New York Institute of Technology - ​Curriculum developed by Professors from Stanford, Columbia, Chicago School of Business, London School of Economics & Carnegie Mellon A ​ ll courses​ ​completed, at a level of honors with distinction: Corporate Finance, Business Communications, Marketing Management PROFESSIONAL TRAINING: ● ● ● ● ● ● ● ● ● ● ● ● ● LEAN and Six Sigma courses including D ​ MAIC, PDCA, K ​ aizen, TPM, RCA, OBC, A3, 5-S (Online courses through LinkedIN as well as in person with company sponsored training) Continuous Improvement Process (MIP) Advanced CI leader training (Georgia Pacific) Kepner Tregoe Analytical Trouble-Shooting - Root Cause Analysis (RCA) training TapRoot Human systems / Accident Investigation RCA training OSHA VPP Star Certification annual training (Once per year for 7 years) Leadership Training level I, II and III (Georgia Southern University) Leadership Training (DDI professional development – Smurfit-Stone) Leadership Training for Management Development Program (International Paper) Market Based Management Training (Koch Industries / Georgia Pacific) Civil Treatment for Managers (Georgia-Pacific) Paper Machine Maintenance School (Valmet Corporation, Beloit, WI) International Paper STOP safety training Corrugator Operations and Maintenance Seminar (Langston Corporation) EXPERIENCE: Owner & Principal Consultant - Precision Industries LLC - Pulp & Paper Engineering Consulting​ Savannah, GA - M ​ arch 2018 - Present Long term contract with ANDRITZ, Inc. ● ● ● ● ● ● Serving as a Senior Reliability and Maintenance Improvement Subject Matter Expert for ANDRITZ PMP North America, in which I am leading teams of Engineers to implement a wide array of improvement initiatives at Pulp & Paper mills across North America Review all project proposals for SOW, deliverables, performance guarantees and T&C to insure the maximum success on each and every project Involved regularly with preliminary discussions and business development meetings with Executives, managers and engineers whom are the key gatekeepers for purchasing PMP contracts Led the design, planning and implementation of a comprehensive OBC (Operator Basic Care) program across an entire mill Led the creation and deployment of a systematic prioritization, RCA deployment, tracking and documentation program using the A3 LEAN format Led ongoing improvement initiatives that are currently on: Batch digesters, Continuous (Kamyr) digesters, Brown stock and Bleach washers, CLO2 mixing, knotters, screens, black liquor recovery, Kappa optimization, CLO2, H2O2 & NAOH usage reduction ● ● ● ● ● Leading the engineers and clients through structured RCA processes to eliminate large, one time, and chronic equipment failures Devising and implementing a LEAN project to reduce chip and Kappa variability at a Pulp Mill in British Columbia Overseeing an Asset Strategy deployment initiative to establish best practices to standardize Preventative Maintenance work integrating with the ABB CMMS for each asset and sub-component Utilizing a proprietary data collection & analysis software that uses process correlations to detect equipment problems proactively, preventing unplanned equipment failures In 6 months, increased reliability on brown stock and bleach plant washers to save over $5 million annually for a mill in the Southeast US. Individual shorter-term contracts ● ● ● ● ● ● ● ● ● ● ● ● Contracted by PMPoland to as SME for a technical review and presentation to their customer in Surabaya Indonesia to finalize the design for a new Brown bag paper machine project in south-east Asia Performed a detailed design review, verification and recommended design modifications for the new paper machine delivery in south-east Asia Contracted by PMPoland for a Paper machine optimization project working for at their customer’s mill site in Taiwan Providing Senior Management & Engineering consulting services to several clients for preliminary engineering and construction planning for new and brownfield Paper Mill projects. Completed a Suction Pressure Roll Failure analysis project for a Paper Mill with machines running over 6000 fpm, running 100% Recycled Fiber Consulted to CEO of a new consumer products start-up company on a product development plan for new recycled fiber and rapidly renewable fiber product his company is bringing to market Consulted to the Director of Technical Applications of a European based Paper Machine company for new project proposals Partnered with an air handling engineering design company (former Valmet colleague) to design and implement new and improved Paper machine dust control and sheet handling solutions Partnered with a British Automation Engineering firm on projects they have in Pulp and Paper mills in the US and carribean. Prepare RFQ’s, review contractor proposals, build job plans, oversee contractors for scheduled shut-downs and mill outages Consulted to a start-up plant producing moulded pulp packaging. They had all of their equipment 100% China sourced and needed support for improved commissioning and overall process optimization. Contract General management role for a Controls & Automation Engineering company with a focus on cost reduction, revenue increase, employee development and establishment of a more strategic long-term business plan Long-term contract with Kredit Automation & Controls ● Contract Project Manager for Controls & Automation Engineering company. Regularly reviewing and approving proposals, contracts & quotations. Overall project execution responsibility on all new projects. Average number of projects simultaneous under management = 35, with new project contracts being executed weekly, 60+ project proposals submitted. ○ As GM, oversaw an overall revenue growth from 2017 to 2018 of 39%, with only a 5% increase in headcount ○ Was part of a three person team who generated all the sales proposals for the company. - Reviewed all sales proposals before they were submitted to the customer - Led negotiations with customers on pricing and deliverables - Regularly involved with pre-sales meetings and conceptual design reviews - Composed or reviewed over 100 proposals in a 9 month period ○ Some top projects included clients in Aerospace, Food processing, Packaging plants, Plastic extrusion, semiconductor and 5G antenna technology as well as many others ○ Top clients included Honeywell Aerospace, UTC , US Air Force, Sargent Aerospace, Intel, Rogers, International Paper, WestRock ○ ○ ○ Over the first 9 months as GM & PM, oversaw 70+ successful projects, all with 25% net profit or higher (average net profit of 45%) Project sizes ranging from $15K to $15million Projects included robotics, PLC’s, as well as turn key deliveries including supply of mechanical components, installation & start-up. Vice President of Manufacturing, ​Solaris Paper Incorporated Buena Park, California, ​October 2016 – March 2018 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Complete P&L Responsibility for (3) Tissue converting plants located in CA, VA and OK Responsible for all aspects of Safety, Production, COGS, Quality Assurance, Product Development, Engineering and Logistics for these (3) Converting plants with annual tissue, towel and facial production volume of 112,000 metric tons/year and a total annual revenue of $270MM. In under one year, reduced overall COGS by $28MM through management restructuring, renegotiation of raw materials contracts, plant to customer supply chain optimization, improved employee development / training and focused coaching of mid-level managers. Led a 43% production improvement for all sold-out lines After my first year, our company was presented a Safety award given by our worker’s compensation company, which recognizes their top 1% of safest or most improved clients. Oversaw Project management team - from Feasibility analysis through procurement on a portfolio of engineering projects to: ○ Build detailed specifications and procure (5) new tissue converting lines ($52 million CapEx budget) ○ Detail design engineering of a new converting plant, 850,000 sq ft, in which we relocated (9) converting lines from the previous plant in Southern California. ($38 million CapEx project) Directly coached and mentored our Engineering Managers, Senior Engineers and new engineers on best practices for project & process engineering including: planning, design, Process Flow Diagrams (PFD’s), P&ID’s, heat & material balance calculations, scheduling, Gantt Charting, project estimating and budgeting. Transformed the safety culture which resulted in reduction in OSHA recordable rate company-wide from 2.8 OIR to 1.3 OIR and approximately $450,000 in savings of Worker’s compensation insurance rates & earning top 1% award from our insurance provider. Rebuilt the Quality management team and quality systems to fully integrate LEAN - Six Sigma processes: Statistical process control and Root Cause Analysis in how we manage quality. Developed several new Base Paper grades to target premium quality Kitchen towel, Bath Tissue, Facial Tissue and Hard wound towel market sectors. Work very closely with paper mills to optimize machine run settings to maximize the quality base paper to be converted. Implemented a company-wide bonus incentive program that each department is eligible for payout at the end of every month, resulting in a significant step change improvement in employee engagement Screened, recruited and hired several key engineers and managers to help with the massive transformation underway to improve safety, productivity, quality, costs and new machine installations. Frequent coaching of managers and engineers for the project engineering and personnel recruiting and hiring strategy for (5) new lines and (2) new plant locations. Oversaw the successful acquisition and restart of a converting plant in the central U.S. Coaching and mentoring regularly a team of 390 employees consisting of managers, engineers, product development specialists, Electro-mechanical technicians, machine operators and material handlers. Oversaw a supply chain team for importing both finished product and Jumbo Tissue rolls from Asia into Ports in California and Virginia. Worked very closely with the CEO and other Vice presidents of Marketing, Sales and Finance to develop strategic direction and an ongoing 5-year plan Led the development of new premium products with the highest demand in the tissue & towel market at the largest possible net profit Site Leader - Greenfield Mill, projects, start-up and overall ops. manager, ​Orchids Paper Products Barnwell, South Carolina, ​March 2016 – September 2016 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Responsible for overseeing all aspects of the design, construction, installation, commissioning and operation of a new Greenfield Paper Mill start-up, with a total project cost of $180MM Oversaw construction, commissioning and operations for (2) Modern, State of the art 100+ inch wide surface winding converting lines with equipment supplied by Futura and TMC/TEC Oversaw engineering, construction and commissioning for: (1) Modern, Flexographic offline printer supplied by Futura and (1) Valmet NTT/QRT Towel Machine Oversaw engineering & construction of a De-inking,recycled fiber plant with state-of-the-art technology, designed and delivered by Valmet to allow for running of any mix between 100% post-consumer recycled fiber up to 100% virgin pulp Oversaw design and construction of complete Wastewater treatment system being Designed and Installed by Voith-Meri Oversaw Construction and establishment of Raw Materials and Finished product storage buildings and implementation of inventory control systems Oversaw the training plan for 115 plant employees Completely revamped the screening process for the hiring of full-time hourly employees in converting, tissue making and de-ink pulp processing areas Screened, recruited and hired a salaried staff of (10) Engineers, Supervisors and managers. Provided regular coaching and mentoring to our internal engineers as well as the contracted process engineers (Valmet) on best practices for: Equipment specification, process design, PFD’s, P&ID’s, heat and material balances, hydraulic calculations and more. Regular design review meetings with Valmet, Poyry, M3 construction which involved man iterations of reviewing and modifying overall plant 3D models Mentored the Maintenance leaders to build out the Mechanical and E&I maintenance team and systems (CMMS, Reliability Centered Maintenance, Total Productive Maintenance, Non-destructive testing, Vibration Analysis, Oil Condition Monitoring) Implementing major improvements to the new employee training processes to reduce the time needed to build operators’ capabilities and shorten the start-up curve for the optimization of productivity of the Tissue machine and converting lines. Implemented a progressive, transparent performance management system to better manage performance and prevent it from becoming only a bi-annual formality. Coaching and mentoring the team of 10 salaried employees weekly to achieve the highest possible performance results. Senior Process Lead Engineer - Subject Matter Expert, ​Amec Foster Wheeler (now part of Wood Plc) Atlanta, Georgia, J​ uly 2013 – March 2016 ● ● ● ● ● ● ● ● Paper Machine and Recycled fiber systems subject matter expert for AMFW’s global Power & Process Engineering group Key Leader for business development of new projects across North America for Pulp and Paper Led process engineering team on multiple Paper Mill design projects including: Process Flow Diagrams, Reviewing P&ID’s, Material & Flow balance calculations, pump calculations, defining detailed major equipment lists, writing up detailed equipment specifications, Pipe sizes, pipe runs, Specifying major equipment such as Paper machine presses, recycled fiber screens, refiners, vacuum pumps, cooling towers, heat exchangers Led the construction management of a newly built Brownfield OCC & stock prep plant for a Newsprint to Linerboard conversion outside of Chicago. Oversaw all trades and managed 7 different subcontractors in the Fall of 2016. Led (3) Front End Loading (FEL) Level 2 Engineering studies for conversion of newsprint machines to containerboard and upgrades to the mills to also include OCC utilization. Led the Process engineering of FEL 2 study for (2) new Conventional Tissue machines at an existing mill in the U.S. with estimated start-up of Summer 2015 Process lead for FEL 2 study for the design & construction of a Brownfield Tissue Mill with Valmet NTT technology in Calhoun, Tennessee valued at $290 million in Q2 2014 Led a study for a machine rebuild and capacity increase of a 272” wide S-wrap, twin wire dry crepe tissue machine in the central U.S. ● ● ● ● ● ● ● Lead technical consultant for Engineering study to design and construct a brand-new TAD machine for start-up in Q3 2015 Lead technical consultant and presenter to a Newsprint mill in Canada considering converting a newsprint machine to Linerboard grades Performed an energy reduction study to reduce energy usage on (2) large, modern Paper machines in Q3 2014 Lead consultant to perform due diligence for a private equity acquisition of several small stand-alone paper mills Q1 & Q2 2014 Completed study to improve efficiency of (2) white top board machines; Was able to identify opportunities that amounted to $6million annual savings for this client Consultant to tissue producer in Australia. Acting on their behalf to work with their equipment suppliers to a recent rebuild to achieve machine productivity and quality performance guarantees Lead consultant to Paper mill in the process of implementing a Valmet designed co-generation system Process Specialist & Product Manager, M ​ etso Paper USA, Inc. (Now Valmet) Biddeford, Maine, A ​ pril 2008 – July 2013 ● ● ● ● ● ● ● ● ● ● ● ● ● ● Served as Product manager for ceramic creping blades after Valmet acquired Pacific blade Co-developed a very high quality ceramic creping blade that performed as good or better than the market leading ceramic blade supplier. Worked closely with the Ceramic R&D team in Finland to formulate the best possible ceramic composition and thermal spray techniques for maximum blade tip performance. Worked closely with other product managers to deliver solutions in spare parts, coater rods, roll services, Yankee systems, Headboxes, Hot Air Systems, Dry End systems, dust collection, sheet handling, tail-threading, calendaring, fiber processing, etc. Conducted process improvement audits as a paid service and as part of corporate agreements to improve safety, quality, productivity and cost reduction at numerous mills across North America. Performed capacity studies and bottleneck analysis as paid service to customers looking to improve speed and production output of their paper machines. Troubleshoot and optimize various systems on paper machines to satisfy performance guarantees, optimize machine productivity and improve customer satisfaction for products delivered. Conducted a process study to improve several paper quality characteristics for a masking tape paper machine. Led several headbox improvement projects including refurbishment and retrofit to dilution profiling headbox for vastly improved profile control and energy savings Served as the reference manager for a new, Valmet paper machine project that started up in spring of 2013 with the primary focus of satisfying a wide array of Valmet performance guarantees. Served as the lead technical resource for Valmet in North America for Yankee creping and coating systems to ensure Yankee dryer protection, eliminate chatter, improve runnability and sheet quality. Developed comprehensive, unique and very effective methods for reducing or eliminating chatter. Worked closely with the Yankee Inspection, metallizing and grind service technicians. Performed Yankee internal inspections, set soda straws, measured run outs, head tilts and inspected the Metallized coatings of numerous Yankee dryers. Supported Dryer cylinder grinding and NDT team as needed with customer technical support and determining causes for Yankee problem areas that are requiring excessive Yankee grinding. Advised customers and Valmet engineers on set-up crepe, cut-off and cleaning doctor profiles for customers as a service on a routine basis, as part of a new machine start-up or in conjunction with a Yankee grind. Advised design engineering on specific preferred machine configurations and design features when developing scope and engineering a new machine or capital aftermarket equipment. Site Leader, Greenfield Mill Start-up & Project Leader, ​Doubletree Paper Mills, LLC Gila Bend, Arizona, ​October 2006 – April 2008 ● ● Responsible for the planning, technical direction, personnel screening, hiring, training, permit processing, infrastructure development & ongoing management for the green-field start-up of a $85 million paper mill. Screened and interviewed over 250 job applicants in order to hire 40 exceptional candidates to fill mill positions. ● ● ● ● ● ● ● ● Provided technical direction, in cooperation with Metso, Spirit Construction, Baisch Engineering and Kredit Automation to design and construct the mill for optimal operation while remaining within budget requirements. Identified high quality refurbished effluent treatment equipment not included in the Spirit Construction original scope but required to keep the mill running with the designed effluent in continuous operation. Created a comprehensive skills development program for 45 new hires, 43 without any experience in the tissue industry in all necessary aspects of the operation of this new mill. Collaborated closely with all Metso start-up resources to commission all Metso purchased equipment: tissue machine, steam system, hood/hot air system, hydraulic system, Metso DNA (DCS, MCS, QCS & Data Historian systems). Worked closely with all Spirit Construction start-up resources to commission all Spirit purchased equipment: i.e. package boiler, Andritz disc refiner / Turbomix tank / HD cleaners, ABB drives, process instrumentation, process pumps, drives, starters, vacuum pumps, package boiler and steam/condensate system components. Achieved a production rate of 85 tons per day within 1 month of the first attempt to put “stock on” the machine, also while running a basis weight of 11.5 lb/3000sqft. Produced a high quality 11.0 gsm tissue within 4 hrs of the first attempt to make that grade. Within 4 months after start-up date, achieved a production rate of 82 tons/day on 9.0 lb tissue, 92 tons/day on towel with speeds up to 5950 fpm and 102” trim width. Georgia Pacific LLC, Rincon, Georgia, April 2000 – October 2006 Positions held: ● Converting Area Production Manager: April 2000 – May 2002 ● Paper Mill (5 machines) Maintenance & Reliability Coordinator: ○ May 2002 – June 2003 ● Paper Machine #20 Assistant Superintendent: June 2003 – March 2004 ● Paper Machine #20 Operations Manager: March 2004 – February 2005 ● Paper Machine #20 & #18 Operations Manager: February 2005 – October 2006 ● Responsible for managing safety, employee development, production, quality, maintenance, budgeting for a 276” Twin-wire, C-wrap, Beloit Paper Machine running up to speeds of 6100 fpm ● Led team to increase productivity by: 15% within the first 3 months of taking over management of the business unit area and 33% within the first 10 months ● Achieved numerous daily, monthly & annual production records on #18 PM (Machine producing an average of 265 tons per day after 14 months of optimization efforts) ● ​Motivated crews to believe they can achieve results that were not thought possible in the past ● Discovered methods to continually improve machine runnability and break through drying limitations, including new retention aids, hood optimization, felt conditioning improvement, steam-box optimization, starch utilization, re-commissioning & optimizing the reel slitting system ● Recruited by the corporate engineering mill tissue process improvement group to join their team but was asked to stay and continue to make improvements at the Savannah Mill ● Was able to still work on special projects corporate engineering group and serve as the lead coordinator of the optimization activities of “speed probes” on several tissue machines to debottleneck those machines and identify further opportunities ● Was assigned to a project in converting to lead a team of managers, technicians, mechanics and operators to improve the productivity on the 2 most profitable converting lines with a target to achieve production targets within 90-120 days. The team was able to exceed the project objectives in only 4 weeks and I was then asked to return to my permanent role overseeing management of #20 & #18 PM’s. ● Oversaw the installation and start-up of a $3 million Voith fine screen & GL&V disc save-all project to improve productivity and reduce fiber cost by achieving improved stickies removal and consistency control ● Responsible for managing safety, employee development, production, quality, maintenance, budgeting for a 276” Beloit Concept IV Crescent Former Tissue Paper Machine running up to speeds of 6100 fpm and 260 tons/day. ● Responsible for managing machine clothing (felts, wires and dryer screens) for all (5) paper ● ● ● ● ● ● ● ● ● ● ● ● machines at the mill; including budgeting, forecasting, inventory management, trial coordination, clothing optimization and requisitioning. Achieved several production milestones including daily and monthly tonnage records Completely redesigned sheet handling foils for improved sheet stability at higher speeds, moving the speed ceiling up 200 fpm on all grades ​Implemented temperature control on calendar hydraulic oil for improved crown control ​Coordinated installation of zone stops and light curtain on winder to improve operator safety ​Manage Measurex QCS Maintenance account, contract and personnel for (5) Paper Machines ​Led employee empowered process improvement teams to drive productivity improvements by having employees develop solutions to common problems and personally implement them. ​Responsible for coordinating maintenance activities on (5) 276” Tissue Paper Machines and supporting equipment with a combined average throughput of over 1350 tons/day Co-managed an annual maintenance spend budget of $7 million; work closely with engineering and accounting to properly manage capital and extraordinary expenses Championed Root Cause Failure Analysis on major and repetitive failures that occur on any of the (5) Tissue paper machines at the mill Served as the “Break-through Specialist” on (2) MIP teams for #19 MPP improvement ​Led post shut-down critiques to ensure job completion and timely start-up Managed Paper Machine clothing (press felts, wires, dryer felts) inventories, invoices, trials, conditioning projects, shut-down inspections, auditing uhle-boxes, rolls, doctor blades, ceramics ● C​oached 50 converting employees to achieve 14 months without any OSHA recordable injuries ● Responsible for management of 4 Tissue Converting Lines including the following equipment: 4 - 250 series, 134” PCMC winders, 2 - Hayssen Twist N’ Tucks, 2 - Valley Tissue Packaging single roll wrappers, 2 - Hayssen Ultraflows, 1 - Hayssen EPS Ultraflow, 3 - Salwasser case-packers, 1 - Schneider case-packer, 1 - Marq sealer, 2 - 3M Tapers ● Appointed January 1​st​, 2002 as Safety Improvement Manager of Tissue Converting Department responsible for the safety of 209 hourly employees ● ​Managed a maintenance budget of $830,000 and made calculated cuts to save over $100,000 in costs ● ​Improved productivity on each line by 25% - BRT 1, 35% - BR 20, 48% - BRT 3, 83% - BRT 2 ● Leader for numerous Continuous Improvement teams (Overall Mill and Departmental) Ex: Gap Case Team ($250M), Broke Breakthrough Team 1 & 2 ($150M+), Mill Operating Supplies Improvement Team ($2,100M), Camless Meterwind Installation ($163M), Efficiency Improvement on BRT20 ($300M), Core Transfer Optimization ($400M), Break-Through Specialist on Commercial Rebranding MIP Team ● Guided hourly personnel on the first 2 Waves of MIP in our Mill: Tissue Quality MIP Team which had reduced tissue customer complaints by over 40%, Soft N Gentle reduced customer complaints by 83% (From 47 to 8 complaints) TECHNOLOGY SKILLS: Automation & Controls: ● Extensive experience with oversight, project management and implementation of a variety of automation and controls projects including: ○ Rockwell & Siemens PLC controls projects & control panel builds ○ LGV projects for warehouse material handling ○ Robotic projects for Automated engine inspection, palletizing as well as complex part manipulation - Experienced with ABB and Fanuc robotics platforms Software: ● ● ● ● Proficient with Microsoft Office (PowerPoint, Excel, Word, Access, Outlook, Project, Visio) Proficient in the use of SAP accounting, WMS and CMMS in various platform varieties Proficient in the use of MiniTab for SPC, correlation and data analysis Proficient in the use of a variety of trending & process data monitoring historians including – PI, Andritz Metris, Valmet DNA, Mole, Honeywell, Delta V, Capstone, ABB, Samsara ● ● Experienced in the use of the following design softwares: AutoCAD​©​ rel. 13, 14, LT; Pro-Engineering FEA & design software, Amipro, Lotus Notes, C-programming, Convergence Training software, Factoryware​©​ production tracking software, Macola​©​ inventory management Proficient with Georgia Pacific ABB/INDUS Passport© Maintenance, Inventory and purchasing System as well as these other CMMS systems: SAP©, Maintenance Connection©, Maintenance Express​© OUTSIDE ACTIVITIES: Represented the Georgia Pacific Paper Mill department on Mill’s United Way committee in 2000 & 2001 years; raised $118,000 in 2000, raised $135,000 in 2001. Was elected by GP leadership team as Mill’s United Way Campaign Leader in 2002, which raised a record $168,000 Regularly conducted tours of The Savannah River Mill with customers, brokers, salespeople, students, Effingham county Chamber of Commerce and The Board of Directors of Georgia Corporation Volunteered with Junior Achievement by going to local schools and teaching lesson plans Volunteered at the local middle school to work with students for Science Olympiad competition Volunteered as labor for proper food storage and distribution at the local Effingham food bank