Stuart L. McDonald2508 W Old US HWY 50Washington, In. 47501812-254-5838cell 361-746-8150 stuartlmcdonald@aol.com

Process / Production EngineerProject Management / Design / Development / Testing / ImplementationPVC / Computer Simulation/ Relief Device Sizing/P&ID Development

A seasoned engineering professional with ‘in the trenches’ experience in world class, high technology manufacturing environments of Borden Chemicals and Plastics, Westlake PVC, BFGoodrich, and Formosa Plastics companies. A proven track record of success in process engineering, production, and production supervision. Expertise in the development and support of high precision manufacturing processes and product development processes.

Generated plant record production of well over 500 million pounds of PVC. Reduced manufacturing anomalies 40% through reengineering of manufacturing procedures. Achieved 95% waste recovery of PVC solids during manufacture of resin. Averted loss of customer account by reengineering of manufacturing processes.

Experienced in all phases of manufacturing to encompass engineering, prototype development, test, production, QC, materials management, company-wide MRP integration, cost controls, purchasing and vendor/contractor negotiations.

BS, Chemical Engineering, Rose-Hulman Institute of Technology, 1979

Professional Achievements

Generated plant record production of well over 500 million pounds of PVC. Developed procedures to minimize downtime and maximize on-stream time and productivity including adjusting batch initiator loads and carefully co-coordinating maintenance efforts to minimize equipment downtime.

Reduced manufacturing anomalies 40% through reengineering of manufacturing procedures. Began flushing of blend tanks between product changes eliminating Inherent Viscosity (IV) non-compliance.

Achieved 95% waste recovery of PVC solids during manufacture of resin. Installed new equipment capable of producing sufficient pressure and flow rate to eliminate excessive carry-over of PVC resin.

Reengineered manufacturing processes averting loss of customer account. Tightened controls over original and standard formulations reducing the failure rates of manufactured parts.

Eliminated quality control problems through establishment of real-time relationship with raw material supplier, DOW Chemical. Arranged for proactive supplier notification of changes in their manufacturing processes enabling the revision of formulations in anticipation of the quality shifts.

Career History

Process Engineer, QualexMt. Vernon, In.Oct 12 2015 to April 8 2016

Provide process Engineering Support to client companies for capitol projects. This includes relief device sizing and specifications, hydraulics studies, P&ID development, PFD development, and instrument and equipment sizing and specificatios

Process Engineer, Moore and Associates, Incorporated (MAI) June 2013 to Oct 7, 2015Mt. Vernon, In.

Provide process engineering services for client companies in the chemicals and plastics industries. The Specific work includes, but is not limited to, relief device sizing, hydraulics studies of piping systems, material and energy balances, developing equipment specifications, P&ID development, and instrument specifications.

Process Engineer, PCI Skanska April 2012 to May 2013Evansville, In.

Provide consulting engineering services for clients, largely in the metro Evansville, In. Area. The Specific work includes, but is not limited to, relief device sizing, material and energy balances, developing equipment specifications, P&ID development, and instrument specifications.

Process Engineer, Formosa Plastics Corporation September 2010 to April 2012Point Comfort, Tx Specialty PVC UnitProvide Engineering support for a new 180,000 tons per year specialty PVC manufacturing plant. This support includes, but is not limited to, participation in PHA reviews, DCS sequencing trials, procedure writing, evaluation of new processing methods, and production start-up support.

Process Engineer, IDEA, Inc. March 2006 to January 2009Provide consulting engineering services for clients. Primarily for clients in the Mt. Vernon, Indiana area. The largest client being Sabic –IP, formerly GE Plastics. Small capital projects (under $10 million) for Sabic include work in the polycarbonate process, Phenol plant, waste water treatment, specialty polymer plant, and others. The Specific work includes, but is not limited to, relief device sizing, material and energy balances, developing equipment specifications, P&ID development.

Process Engineer, R&D Consulting January 10, 2005 to March 2006Provide consulting engineering services for clients. Specific work includes, but is not limited to, relief valve calculations for the Monochem, Inc. utilities plant, pipeline sizing for Ineos’ refrigerant R22 railcar unloading system, material and various capital projects for Rubicon, a Division of Huntsman chemical that produces di-isocyanates for polyurethane production.

Explosives Handler US. Army March 2003 – Jan 2005Worked for the United States Army as a civilian employee in materials handling.

Process Engineer/PVC Production Superintendent: Borden Chemicals and Plastics, 1993-2002As Production Superintendent, organized and led daily operations of PVC manufacturing plant. This includes direct supervision of four shift supervisors and one day supervisor, and indirect supervision of 26 shift workers. As a Process Engineer, supported manufacturing units of three sites (these are the Illiopolis, Il., and Addis, La. PVC plants, and the Geismar, La. complex which included PVC and VCM units, as well as methanol, ammonia, formaldehyde and acetylene plants). This support included, but was not limited to, providing engineering troubleshooting and process design. Developed scopes of work for capital projects, and developed PFDs and P&IDs for these projects. These projects include, but are not limited to, hydroclones for the Addis plant waste water system, and the HCl emissions reduction project at the Geismar VCM-E plant. Experience as a team member for the Geismar site hazard analysis (“HAZOP”) program, and helped develop guidelines for implementation of OSHA 1910 Hazardous Chemicals program.

Production Superintendent: Westlake PVC, 1991-1993Responsible for daily operations of PVC manufacturing plant including quality control and productivity.

PVC Production Engineer: BFGoodrich Company, 1979-1991Oversaw quality and productivity of PVC process spanning four plants and PVC production units. Worked with R&D and Marketing to develop/implement new products and processes.