Cathy Erwin
Evansville,IN
Summary
Seasoned BPA Operations Lead at SABIC Innovative Plastics, leveraging 20+ years of expertise to pioneer over 100 SOPs and certify 11 operators, enhancing process efficiency and safety compliance. Renowned for innovative training methods and adept at interactive teaching, significantly reducing onboarding time while fostering a culture of continuous learning and improvement.
Overview
43
43
years of professional experience
1
1
Certification
Work History
BPA Operations Lead (Training)
SABIC Innovative Plastics, GE Plastics
Mt. Vernon , IN
10.2021 - 05.2024
- Trained new and existing operators on troubleshooting process equipment issues, as well as production issues. The BPA manager utilized my 20 years of operating a BPA unit to help identify process issues and train operators on BPA troubleshooting skills. When training on troubleshooting process issues through lab data, discussions with the operating team, and monitoring the process via the Distributed Control System in the control room. This requires a deep understanding of chemical process equipment.
- Training new and existing operators, and day staff members, to ensure they have the necessary resources, training, and support to carry out their roles successfully. This included training for the SOPs that pertained to their specific roles, and safety training for any new staff in the BPA operation. Aside from training on SOPs, I also trained new and existing operators on various types of equipment used in chemical units, such as distillation columns, pumps, piping, reactors, conveyors, compressors, and many other types of industry equipment.
- Leading a team to ensure operational processes and procedures are followed efficiently and effectively. As the operations lead for training, I personally developed over 100 standard operating procedures and actively trained existing and new operators on these SOPs. In BPA, I developed a new training policy for all new hires and existing operators to ensure operations personnel are trained and aware of the specific hazards in the BPA unit, and the policies in place to protect against unwanted injuries and environmental releases.
- Trained, mentored, and motivated employees to maximize team knowledge of how to operate a chemical unit on a day-to-day basis. To ensure ownership of the training process, I actively involved the operators in the training agenda and SOP edits to ensure the key stakeholders had ownership in the development of training and SOPs.
- Led the development of new operational procedures, and trained new and existing operators on the content of the SOPs. With 20 years of experience working in the BPA process, I utilized my process knowledge to develop well over 100 standard operating procedures. These SOPs detailed how to operate various equipment in the BPA process, such as reactors, pumps, compressors, steam jet packages, distillation equipment, exchangers, etc. Then I trained all new and existing operators on new or updated SOPs.
- Trained new employees on operational protocols, significantly reducing onboarding time by utilizing teaching aids and information from various sources. The training material for new operators was focused on types of process equipment (reactors, pumps, process lines, etc.), while introducing how the BPA unit operated. All new BPA operators were trained by me, following the BPA training criteria. Over a two-year period, I trained and certified 11 operators in the BPA unit. On a site level, I continued to provide new-hire safety training for PSM awareness and safe utility hose use policy.
- Assessed company operations for compliance with safety standards. This was ongoing in the BPA process, as well as at a site level, while I continued to assist the PSM department in PSM audits.
- Worked closely with human resources and work force development to support employee management and organizational planning.
- Developing and implementing effective strategies to optimize operational performance.
- Led regular meetings with team members to discuss progress and identify areas for improvement.
- Identifying process inefficiencies or bottlenecks and developing solutions to improve them.
- Overseeing the implementation of new systems or technologies that were introduced to the BPA process. All process changes would require updates to existing or new SOPs. I developed these while working closely with the unit engineers, site technologists, and operators.
- Coordinating the recruitment of new personnel as required by business needs through new employee interviews and assessments.
- Providing guidance and mentorship for junior staff members, especially in the BPA unit. There were many young operators in BPA who required extra patience and different training methods to ensure the operators did not get bored or overwhelmed with process training.
- Actively participating in planning sessions for new projects or initiatives.
- Facilitated team meetings to discuss operational challenges and brainstorm solutions.
- Conducted regular performance evaluations, providing feedback and development opportunities to staff to determine if an operator needed additional training.
- Maintained positive working relationship with fellow staff and management. This required day-to-day interaction and an understanding that each person in the operation required different kinds of interaction.
- Utilized document management system to organize company files, keeping up-to-date and easily accessible data.
Process Safety Specialist
SABIC Innovative Plastics, GE Plastics
Mt. Vernon , IN
07.2010 - 10.2021
- Developed and implemented process safety management systems to ensure compliance with regulatory requirements. One of the many responsibilities as a PSM specialist was auditing the various units across the Mt. Vernon plant site to ensure gaps in OSHA/PSM compliance were identified and addressed. I also assisted in the auditing process of SABIC sister plant sites in Burkeville, Alabama, and in Ottawa, Illinois.
- Trained all new hires on the PSM regulation as part of employee participation requirements.
- Conducted hazard identification, risk assessment, and consequence analysis of existing processes using the Process Hazard Assessment tool. As a certified PHA leader and facilitator, my main responsibility was to evaluate whether the site units met an acceptable SABIC risk tolerance using a "cause and consequence" PHA tool. If a specific risk or risks were identified that were outside of an acceptable risk, I developed recommendations to the site management to meet the risk tolerance, as SABIC dictated. I personally facilitated over 100 new PHAs for SABIC in MTV, and several in Burkeville, Alabama, and Ottawa, Illinois.
- Trained a new PSM specialist and new PSM engineer on the PSM elements, along with how to facilitate PHAs.
- Reviewed engineering drawings to identify potential hazards and develop control measures. One of the PSM elements that is closely monitored is Process Safety Information (PSI). Process instrumentation drawings (P&IDs), also known as engineering drawings, are the road map for every chemical unit. P&IDs are utilized in the PHA process as part of the risk identification tool, and we would use these in my PHA studies. As a site PSM specialist, I would audit P&IDs across the site for gaps in correct information due to process changes. I also trained new engineers and operators on how to read and understand P&IDs.
- Trained all new hires on the safe handling of chemical hoses and the process line clearing policy. This policy is called E.01, and I managed this policy until I retired.
- Provided technical support for the design and installation of new process safety equipment using the Management of Change (MOC) process and the PHA process. MOC is one of the PSM elements.
- Performed incident investigations to determine the root cause and corrective actions using the "5 WHY" method.
- Coordinated internal audits of process safety operations to ensure compliance with regulations. Audited various units across the Mt. Vernon plant site to ensure gaps in OSHA/PSM compliance were identified and addressed, and assisted in the auditing process of SABIC sister plant sites in Burkeville, Alabama, and Ottawa, Illinois.
- Evaluated new technologies for their impact on process safety management systems, using the Management of Change (MOC) process, and the PHA process. MOC is one of the PSM elements, and I was a part of the site MOC team that reviewed, accepted, or rejected changes on site. I led several PHAs for a new process brought onsite to identify unforeseen risks.
- Assisted in developing training programs related to process safety topics through new hire orientation, introducing PSM, which I led. I also assisted the workforce development team in the development of various safety topics as needed.
- Drafted documents such as standard operating procedures, work instructions, emergency response plans. While in PSM, I developed the 3.01 Standard Operating Procedure policy for the MTV plant site, ensuring compliance for PSM and non-PSM SOPs. Though I left PSM as a full-time PSM specialist, I continued to manage the site SOP policy and process.
- Monitored contractor activities onsite for adherence with established safe practices. As a PSM auditor, I was involved in various contractor activities audits.
- Prepared reports outlining findings from investigations or assessments of process safety systems. Once I had completed a full PHA, I developed the executive summary, which detailed any findings and the general safety of the unit. This executive report was then presented to site management and the site maintenance management team.
- Identified opportunities for improvement in existing processes and recommended solutions. At the completion of a PHA or incident investigation, I would develop recommendations based on the risks identified, or the outcome of an investigation, and present these recommendations to site management.
- Participated in industry forums, conferences and workshops related to Process Safety Engineering.
- Tracked changes in relevant regulations and standards issued by governing bodies, following the MOC process.
- Ensured that all necessary documentation is completed accurately according to company policies and procedures.
- Assessed the effectiveness of current controls used in hazardous material handling operations.
- Maintained a database containing information regarding process safety incidents, corrective actions taken and results achieved.
- Verified accuracy of calculations performed during design phase of new projects involving hazardous materials or processes.
- Worked with managers, operators and vendors to perform root cause analysis on failing systems.
- Participated in internal teams to create, improve and standardize processes and equipment.
- Identified and implemented process changes to improve safety, cost and reliability.
- Defined processes with project team to meet performance and cost targets.
- Developed standard operating procedures (SOPs) and trained staff on best practices.
- Participated in the development of new products, providing expertise on process capabilities and constraints.
- Conducted risk assessments and developed mitigation strategies to ensure process safety.
- Designed and executed process validation studies to ensure compliance with industry standards.
- Ensured compliance with environmental, health, and safety regulations in all process engineering activities.
- Prepared technical reports and presentations to communicate findings and recommendations to management.
- Evaluated new technologies and materials for potential application in manufacturing processes.
- Monitored key performance indicators (KPIs) to assess process performance and identify improvement opportunities.
- Coordinated worker training in safety laws and regulations, hazardous condition monitoring and use of safety equipment.
- Coordinated worker training to address safety laws and regulations, hazardous condition monitoring and use of safety equipment.
- Performed worksite safety assessments and made actionable recommendations to update procedures, improve environments and optimize worker behaviors.
- Conducted risk assessments and recommended changes to enhance health, safety, security and environmental facets of different products.
- Analyzed health and safety data to verify safety program performance, identify areas of concern and recommend improvement plans.
- Audited safety protocols and standard operating procedures to meet conformance targets and set operational parameters.
- Executed risk analysis to mitigate hazards and promote safety in and areas.
- Led adherence to internal safety and operational procedures to reduce risks and costs by protecting employees, equipment and property.
- Completed quarterly safety reviews for client offices, optimizing procedures, reducing hazards and achieving compliance objectives.
- Interpreted statistical data related to occupational illnesses and accidents.
- Developed methods and procedures to perform and enhance product safety tests and evaluations.
- Developed and implemented company-wide safety initiatives, driving substantial reductions in identified hazards and incidents with injury.
- Consulted leadership to develop and spearheaded implementation of injury and risk reduction methods and emergency procedures.
- Estimated health, safety, environmental, and security risks of and areas to bring operations in compliance with applicable regulations and laws.
- Evaluated product design and construction, formulated test plans and analyzed test data to determine compliance with applicable requirements.
- Conducted comprehensive site surveys and infection control evaluations of client facilities to identify hazardous conditions while developing corrective action plans.
- Achieved safety compliance across multiple product lines and programs with diligent attention to and parameters.
- Evaluated products within marketplace to mitigate and eliminate workplace hazards.
- Conducted air quality, testing to measure noise, temperature and radiation levels for compliance with health and safety regulations.
- Carried out efficient certification-related activities by interfacing cross-functionally with certification staff from other groups, customers and relevant team members.
- Maintained technical integrity and consistency while ensuring safe delivery of certification services within business unit.
- Managed safety consulting projects, and adhered to project deadlines and milestones.
- Supported personnel training with focus on proper equipment operation and adherence to safety protocols.
BPA Training Coordinator
SABIC Innovative Plastics, GE Plastics
Mt. Vernon , IN
07.2005 - 07.2010
- Trained new and existing employees on training materials and documents, such as manuals, handouts, exercises, and facilitator guides.
- Conducted needs assessments to identify gaps in employees' skills and knowledge in the BPA operators' training and understanding.
- Coordinated with subject matter experts to develop effective training content based on their expertise in the BPA unit and my experience in the BPA unit.
- Organized and scheduled on-site training for staff members new to the BPA process.
- Maintained accurate records of all trainings conducted.
- Provided feedback to OJT trainers regarding the effectiveness of their sessions.
- Assisted in designing, developing, and implementing new training methods and techniques.
- Monitored participants' progress during the training session.
- Evaluated employee performance before, during, and after training sessions.
- Created post-training surveys to assess the quality of instruction received by participants.
- Analyzed current processes and procedures to identify areas for improvement through training initiatives.
- Collaborated with management team to determine appropriate learning objectives for each program.
- Provided ongoing support to internal customers throughout the entire training process.
- Assisted in setting up online learning platforms used for virtual classroom environments.
- Managed training calendars to inform participants of upcoming training session topics and dates.
- Supported onboarding of new employees by hosting orientation sessions.
- Developed targeted courses to achieve company training objectives and enhance skills of new employees in leadership roles.
- Collaborated with department heads to tailor training programs to specific job roles and functions.
- Acted as a liaison between employees and management to communicate training needs and outcomes.
- Conducted skills gap analyses to identify training requirements for different departments.
- Analyzed feedback from training participants to make improvements to future programs.
- Maintained up-to-date knowledge of training trends, developments, and best practices.
- Utilized learning management systems (LMS) to administer online training and track employee progress.
- Designed and implemented comprehensive training programs to meet organizational needs.
- Promoted a culture of continuous learning and improvement within the organization.
- Designed and implemented comprehensive training programs tailored to organizational needs.
- Facilitated engaging and informative training sessions for both new hires and existing staff.
- Developed training materials and manuals to support diverse learning styles and organizational objectives.
- Ensured compliance with industry-specific training requirements and certifications.
- Explained goals and expectations required of trainees.
- Monitored, evaluated and recorded training activities or program effectiveness.
- Scheduled classes based on availability of classrooms, equipment or instructors.
- Participated in and attended meetings or seminars to obtain information for use in training programs.
- Evaluated training materials prepared by instructors and offered actionable suggestions for improvement.
- Assessed training needs through surveys, interviews with employees or focus groups.
- Obtained and organized manuals, guides and visual materials for development and training purposes.
- Selected and assigned instructors to conduct training.
- Maintained strong knowledge by participating in workshops, conferences, and online education classes.
BPA Shift Lead Supervisor
GE Plastics
Mt. Vernon , IN
02.2000 - 07.2005
- Provided leadership and direction to shift staff, ensuring company policies and procedures were followed.
- Ensured all daily operations were in compliance with safety standards and regulations.
- Led in shift oversite of running the BPA plant safe and effectively.
- Created schedules for team members and monitored attendance records.
- Conducted training in equipment operations and safety procedures, including the hazards associated with working in a chemical unit.
- Assigned tasks to employees based on their abilities, skill levels, and experience.
- Performed disciplinary actions when necessary, following company guidelines.
- Conducted performance reviews for shift staff and provided feedback for improvement.
- Resolved customer complaints efficiently by providing timely solutions or escalating the issue as needed.
- Monitored quality of product output to ensure it met customer specifications.
- Trained new hires on job duties, safety protocols, and company policies and procedures.
- Maintained accurate inventory records of products used during shifts.
- Collaborated with management to develop plans for improving productivity and reducing costs.
- Prepared daily reports detailing shift activities including labor hours worked, number of units produced..
- Managed employee breaks and lunches according to established guidelines while maintaining production goals.
- Identified areas where additional training was required to improve employee performance.
- Analyzed data from previous shifts to identify trends in production issues or errors.
- Investigated workplace accidents and incidents thoroughly; prepared detailed reports outlining findings and corrective actions taken.
- Addressed employee grievances promptly; sought assistance from Human Resources if needed.
- Served as a liaison between shift staff and upper-level management; communicated any changes in policy or procedure quickly.
- Coordinated with other departments regarding materials needed for production runs.
- Monitored daily operations for quality and adherence to work order specifications.
- Enforced rules and procedures for accuracy, efficiency and safety.
- Supervised, trained and guided team by coaching on daily activities.
- Communicated daily schedule and delegated work to employees.
- Oversaw monthly site inspections and daily observations to maintain safety, production standards and environmental regulations compliance.
- Documented timecard data, maintenance logs and production logs.
- Collected key performance indicator metrics, analyzed results and offered process improvement recommendations based on data.
- Positioned skilled staff in key areas throughout shift to optimize department productivity.
- Mentored and coached staff by giving employees suggestions and feedback to improve job performance.
- Coached team members to increase productivity and reduce workplace accidents.
- Handled escalated customer concerns and emergencies in absence of manager or supervisor.
- Upheld company standards and compliance requirements for operations.
- Managed daily workflow and scheduled staff for adequate coverage.
- Delegated tasks to employees and monitored activities and task completion.
- Complied with company safety procedures, policies and regulations to promote safe working environment.
- Evaluated employee performance, delivering individualized feedback and praise.
- Assisted general manager with operations game plan and company initiatives implementation.
- Handled emergency situations with composure and in accordance with company guidelines.
- Managed inventory levels and placed orders to ensure product availability and minimize waste.
- Monitored and maintained equipment to ensure operational efficiency.
- Ensured compliance with health and safety regulations to provide a safe workplace.
- Maintained cleanliness and organization of the work area to uphold company standards.
- Fostered a team-oriented environment to increase morale and productivity.
- Coordinated with other shift leaders and management to ensure smooth transitions between shifts.
- Collaborated with management to set performance goals and evaluate progress.
- Delegated tasks to multiple employees while maintaining efficient workplace.
- Read and interpreted work order specifications and information to plan, schedule and carry out jobs effectively.
- Enforced company policies, answered coworkers' questions and trained new personnel.
- Observed and monitored utilization of equipment.
- Assigned tasks to employees and monitored productivity, performance and task completion.
- Directed and coordinated production activities, encouraging employees to meet specifications.
- Set up and adjusted machines and equipment to produce pre-determined results.
- Performed minor equipment repairs to keep jobs on task and notified maintenance department of major machinery failures.
- Conferred with management and subordinates to resolve problems or complaints.
- Recommended opportunities for growth and advancement to motivate employees.
BPA Operator
General Electric Company
Mt. Vernon , IN
10.1985 - 02.2000
- Monitored and adjusted BPA process equipment as needed for production and quality assurance.
- Performed routine equipment preparation for maintenance activities on equipment, such as isolating systems, flushing piping, and equipment.
- Start-up or shutdown, planned or unplanned, of the BPA process and equipment as needed, both on the distributed control system and in the field. This means running the equipment from the control room computers (DCS) or aligning process lines and equipment for start-up or shutdown outside in the field.
- Perform field rounds, checking for good running conditions, or malfunction of equipment in the BPA process. These field checks required the knowledge of what to look for, listen to, or unusual odors that may indicate abnormal conditions, such as pump or compressor seal leaks, gasket leaks, piping and equipment failure, valve packing failure, process safety valves leaking, fouled exchangers, etc.
- Maintained cleanliness of the work area and equipment in accordance with safety policies for good housekeeping.
- Assisted in the setup and startup of production lines according to customer specifications.
- Troubleshooted mechanical problems with machines, making repairs or adjustments when necessary.
- Conducted regular inspections of machinery to identify any potential issues or malfunctions.
Quality Control Supervisor
Mid-American Plastics
Mt. Vernon , IN
01.1984 - 10.1985
- Managed the quality control team of three personnel.
- Trained new employees on proper use of inspection tools and techniques.
- Performed regular maintenance on equipment used in quality assurance processes, such as drills and presses.
- Ensured that safety protocols were followed during all testing procedures.
- Performed inspections on incoming raw materials, such as specific mold pieces, prior to assembly.
- Investigated customer complaints and initiated corrective action plans if poorly assembled pieces were returned.
- Evaluated the performance of Quality Control personnel, identified training needs, provided feedback, and recommended improvements continually and at annual appraisal time.
- Led inspections with quality control team members.
- Scheduled priorities, equipment, workstations, and staff members to meet goals on time for customer needs and inventory.
- Delegated tasks to multiple employees while maintaining efficient workplace.
- Set up and adjusted machines, such as drills and presses, and equipment to produce pre-determined results.
- Performed minor equipment repairs to keep jobs on task and notified maintenance department of major machinery failures.
Food Service Worker
Dairy Queen
Evansville , IN
01.1981 - 05.1981
- Assisted in the preparation of food items according to recipes and instructions.
- Cleaned kitchen areas, equipment and utensils.
- Stocked supplies such as food, dishes, utensils, and cleaning materials.
- Greeted customers upon arrival in the dining area.
- Delivered food orders promptly and accurately to guests tables.
- Prepared beverages such as coffee, tea, soda..
- Maintained cleanliness standards for all service areas including dining room, kitchen and storage areas.
- Adhered to safety procedures when handling sharp objects or hazardous materials.
- Replenished condiments at customer tables as needed.
- Responded promptly to customer inquiries regarding menu items or special requests.
- Followed established cash handling procedures when collecting payment from customers.
- Performed opening and closing duties such as setting up workstations with necessary supplies.
- Operated dishwashing machines safely and efficiently.
- Operated cash register to process cash, check, and credit card transactions.
- Cleaned and sanitized work areas, equipment, utensils, dishes, and silverware.
- Performed variety of duties related to food service.
- Maintained order and cleanliness of work areas to conform with health codes.
- Maintained professional demeanor during interactions with customers and co-workers.
- Received food orders from individuals and explained offerings.
- Wiped down tables and removed trash and dirty plates to provide clean, welcoming dining environment.
- Maintained clean and orderly appearance throughout kitchen and dining area.
- Assembled and served meals according to specific guest requirements.
- Packaged and bagged cooked food and prepared items.
- Refilled condiments, napkins and server workstations.
Education
Foundation of Process Safety
Center of Chemical Process Safety
11-2019
Process Safety Management Compliance And Auditing
ABS Consulting Group
Knoxville, TN10-2018
Advanced PHA Leader And Revalidation
ABS Consulting Group
Houston, TX07-2011
Process Hazard Analysis Leader
ABS Consulting Group
Houston, TX10-2010
Train The Trainer Course
ABS Consulting Group
Knoxville, TN11-2005
Standard Operating Procedure Writing
ABS Consulting
07-2000
High School Diploma -
MT.Vernon Senior High School
Mt. Vernon In05-1982
Skills
- Training delivery to BPA unit new hires and existing operators on the fundamentals of chemical process equipment and how to run a chemical unit
- Training delivery to the MTV site training coordinators on the standard Operating procedure policy requirements
- Training delivery to site new hires for safe use of utility hoses policy and how to safely steam and flush equipment
- Training delivery to site new hires on the PSM 14 elements and how they apply to their jobs
- Interactive teaching and learning new SOPs and policy for MTV site and directly to BPA operators
- Group and individual instruction on required safe permitting such as lock out tag out, vessel entry permitting, line opening permitting, hot work permitting and silo entry permitting
- Testing and grading new and existing operators on chemical plant fundamentals taught with-in the unit
- Class instruction for small and large groups both with-in BPA and on a site level
- Adult learning by incorporating the competency based training method for adult learners
- Innovative teaching methods to ensure a younger generation stays engaged with the training provided such as using MTS training manuals and videos
- Certified PHA leader and facilitator leading many PHAs on and off the MTV plant site
- Trained PSM subject matter expert and auditor
Affiliations
- I enjoy many different hobbies, such as boating, kayaking, camping, fishing, and traveling
Accomplishments
- While working as an operator in the BPA process, I was able to develop a production project that made the company $140,000 extra for that year, and I was awarded a $14,000 suggestion award
- When returned to BPA as the Operations lead for training, I was able to train and certify 12 additional operators as chemical operators in the BPA unit
- While in PSM and managing the site SOP's, I was challenged with bringing the site over due for reveiw SOPs back into compliance in regards to overdue 3 year reveiw and approvals. There were over 1,000 overdue SOPs at that time when I developed a plan to bring these into compliance Working closely with the site training coordinators we were able to bring all SOPs in compliance in less than a year meaning none overdue for approval.
- Due to my effort to bring the site SOPs in compliance, I was awarded SABIC employee of the year in 2020.
- As a PSM PHA leader, I facilitated well over 100 PHAs, including new projects brought to the MTV plant site
- I enhanced the E.01 safe hose policy for the MTV site, and trained many operators on how to safely steam and flush process equipment This policy was created after the death of my cousin on the MTV plant site in 2007.
Certification
- I am a certified PHA Advanced Leader
- I am a certified PSM auditor
References
References available upon request.
Timeline
BPA Operations Lead (Training)
SABIC Innovative Plastics, GE Plastics
10.2021 - 05.2024
Process Safety Specialist
SABIC Innovative Plastics, GE Plastics
07.2010 - 10.2021
BPA Training Coordinator
SABIC Innovative Plastics, GE Plastics
07.2005 - 07.2010
BPA Shift Lead Supervisor
GE Plastics
02.2000 - 07.2005
BPA Operator
General Electric Company
10.1985 - 02.2000
Quality Control Supervisor
Mid-American Plastics
01.1984 - 10.1985
Food Service Worker
Dairy Queen
01.1981 - 05.1981
- I am a certified PHA Advanced Leader
- I am a certified PSM auditor
Foundation of Process Safety
Center of Chemical Process Safety
Process Safety Management Compliance And Auditing
ABS Consulting Group
Advanced PHA Leader And Revalidation
ABS Consulting Group
Process Hazard Analysis Leader
ABS Consulting Group
Train The Trainer Course
ABS Consulting Group
Standard Operating Procedure Writing
ABS Consulting
High School Diploma -
MT.Vernon Senior High School
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