Summary
Overview
Work History
Education
Skills
Certification
Professional Training
Affiliations
Timeline
Generic

James C. Copenhaver

Glade Spring,VA

Summary

Experienced leader with strong background in guiding teams, managing complex projects, and achieving strategic objectives. Excels in developing efficient processes, ensuring high standards, and aligning efforts with organizational goals. Known for collaborative approach and commitment to excellence.

Overview

38
38
years of professional experience
1
1
Certification

Work History

Corporate Sr. Automation Engineer (Hybrid)

SIG
06.2019 - Current
  • Company Overview: SIG is the industry leader for bag-n-box producing bags for Coca-Cola syrup concentrate bag-n-box
  • Lead $15M capital project expanding manufacturing facility 50,000 sq.ft
  • Managed $35M capital project expanding manufacturing facility 72,000 sq.ft
  • Including the installation of three 3-layer blown film lines
  • Lead $7M capital project installing 2 bag lines to support growth in Bag-in-Box
  • Installed 7 injection molding presses processing HDPE and LDPE to produce caps and flanges for bag-n-box manufacturing
  • Provide global support to SIG production facilities for production equipment purchases, design recommendation based on application, automation initiatives and SQF requirements
  • Injection molding, Profile extrusion, Automatic bag machines, Automated packing, and Custom assembly equipment
  • Evaluated new technologies in the field of automation engineering, making informed recommendations to drive company growth.
  • Presented project progress updates to stakeholders at regular intervals, maintaining strong communication channels throughout development cycles.
  • Reduced manufacturing downtime with proactive maintenance strategies and effective troubleshooting of automation equipment.
  • Mentored junior engineers, providing guidance on best practices for automation design and implementation.
  • Assisted in employee training programs focused on proper operation of automated equipment, fostering a more skilled and informed workforce.
  • Led the installation of new production equipment, coordinating efforts across departments to ensure smooth integration into existing workflows.
  • Work with plants using TPM’s Early Equipment Management for the selection and purchase of production equipment
  • Manage capital projects from selection to Factory Acceptance Testing (FAT), installation, Site Acceptance Testing (SAT) and establishing process through DOE
  • Work with maintenance managers in facilities to improve maintenance effectiveness
  • Design and build production equipment with improved reliability, increased capacity and fast changeover following the SMED principles


Technical Manager (Engineering & Maintenance)

SIG
11.2008 - 06.2019
  • Company Overview: SIG is the industry leader for bag-n-box producing bags for Coca-Cola syrup concentrate bag-n-box
  • Through efficiency improvements applying Lean Manufacturing and Six Sigma, reduced labor and improved equipment reliability, increasing margin from 23% to 28%
  • Coordinated with other departments effectively, integrating technical requirements into broader organizational goals seamlessly.
  • Reduced reactive maintenance to less than 3% over the past 3 years
  • Managed implementation of new technological improvements resulting in increased efficiency.
  • 100% completion of Preventive Maintenance over past 3 years
  • Created comprehensive documentation of processes and procedures to ensure consistency throughout the department''s operations.
  • Maintenance and repair spending under budget
  • Prepared status charts for daily management meetings in Excel and PowerPoint.
  • Champion of Six Sigma with 37% of my direct reports Greenbelt certified
  • Spare parts stock out % greater than 99%
  • Implemented annual PM optimization Kaizen, Kaizens are now led by hourly maintenance personnel
  • As a result of reliability focused maintenance, plant realized a reduction in maintenance cost of 3% annually
  • Zero major or minor discrepancies for the technical group during SQF audits from 2017 to 2019
  • Developed maintenance audit process to baseline all North American facilities
  • Installed 7 injection molding presses processing HDPE and LDPE to produce caps and flanges for bag-n-box manufacturing
  • Manage a staff of 16 maintenance and engineering personnel supporting injection molding, profile extrusion, automated bag machines, automated packing and custom assembly equipment
  • HVAC, cooling towers, chillers and material handling systems
  • Work closely with 6-person leadership team to plan annual strategy and support other departments as needed
  • Work with other North American plants to improve maintenance effectiveness
  • Implemented EAM CMMS to include shop floor dispatching for real time data collection and 100% work order coverage
  • Manage capital projects and develop annual capital improvement budget
  • Lead facility safety initiative through Pursuit To Zero


Engineering Manager

Gatorade
04.2008 - 11.2008
  • Company Overview: Hot fill bottler for the sports drink industry
  • Managed capital projects and annual capital project budget
  • Responsible for 2-person engineering team supporting plant operations
  • Identified areas for to improve production through put
  • Work with 7-person leadership management team to set strategy and improve efficiency
  • Worked with PepsiCo engineering on the launch of SoBe Life Water


Engineering/Maintenance Manager

TAMKO Building Products
09.2004 - 04.2008
  • Company Overview: Epoch Composite Products, Chilhowie, VA is a manufacturer of wood/plastic composite decking, hand railing and multilayer extrusion products to the construction industry
  • Served as Acting General Manger (2005-2007) (during GM’s deployment to Iraq) responsible for the performance of 70 personnel.
  • Cut operating costs by $1 million while sales increased 73%; implemented Lean Manufacturing methodologies; served as Six Sigma champion resulting in $2.4M savings; facilitated first Kaizen event in company history
  • Implemented equipment reliability initiatives and continuous improvements resulting in an Overall Equipment Effectiveness of 85%
  • Managed continuous improvement projects resulting in a $270K savings
  • Hired as Project manager of $35M capital budget for the brown field startup of a 600K sq ft facility, included equipment installation, permitting and contractor management. Completed on time and under budget
  • Additional duties include Lean Manufacturing and Environmental Coordinator
  • Supervised employee performance, preventive maintenance, and safety.
  • Direct and manage engineering department responsible for improvements to existing processes, new product development, automation of equipment, R & D trials, new equipment installation and all capital projects
  • Optimized spare parts inventory management by identifying critical items and setting appropriate stock levels based on usage patterns.
  • Utilizing SAP I directed and managed maintenance department including implementation of TPM, PM/PdM, installation of new equipment, troubleshooting and repair of equipment and facilities management and maintenance
  • Increased overall equipment efficiency by conducting thorough assessments of machinery conditions and implementing necessary improvements.
  • Developed detailed maintenance budgets, effectively controlling expenses while ensuring optimal equipment performance.
  • Responsible for the compliance of all federal, state, local and company regulations and policies
  • Manage engineering and maintenance departmental budgets and report KPI’s
  • Develop FMEAs and control plans for new product launches
  • Develop current and future state value stream maps, scope and facilitate Kaizen projects


Maintenance Manager

Lear Corporation
10.1997 - 09.2004
  • Company Overview: Lear Corporation, Lebanon, VA is a tier one supplier to the automotive industry producing injection molded interiors with annual sales of $120M
  • Responsible for the performance of 4 salary and 66 hourly (uniion)staff
  • Implemented MP2, Computerized Maintenance Management Software (CMMS) to develop equipment history, manage PM/PdM programs and utilize personnel more efficiently
  • Improved equipment reliability by implementing a preventive maintenance program and managing repair schedules.
  • Implemented bar coding system for improved MRO inventory control and accurate inventory cost
  • Collaborated with other department managers to coordinate maintenance activities around production schedules, minimizing operational interruptions.
  • Placed $250K of MRO items on consignment having 4 to 6 turns per year
  • Led the successful completion of major facility upgrades projects while adhering to budget constraints and timelines.
  • Decreased downtime by 50% and decreased maintenance cost by $1.5M during 2003 through the implementation of PM/PdM
  • Trained maintenance technicians to apply proper techniques and best practices and comply with safety protocols.
  • Managed plant expansion and equipment installation projects for a program that increased annual sales by $70M
  • Monitored priorities and liaised between maintenance team and management, delegating tasks to complete on time.
  • Wrote and implemented a strategic maintenance plan to guide department to World Class Maintenance status
  • Leveraged data and analytics to make informed decisions and drive business improvements.
  • Installed retrofitted thermoforming press processing wood flour and polypropylene for door panels
  • Put into place shop floor dispatching for maintenance work order system using Web-Link to capture real time downtime and achieve 100% work order coverage
  • Manage 70-person maintenance team supporting injection molding, low pressure molding, Thermoforming and custom assembly equipment
  • Developed monthly maintenance reporting KPI’s for maintenance cost, schedule compliance, reactive maintenance, and labor costs
  • Optimized spare parts inventory management by identifying critical items and setting appropriate stock levels based on usage patterns.

Plant Electrical Engineer

Doehler-Jarvis
04.1997 - 10.1997
  • Company Overview: Doehler-Jarvis is an aluminum die-casting manufacturing facility supplying engine components to the automotive industry
  • Supported all production departments on electrical controls implementation such as PLC & HMI programming, electrical pneumatic and hydraulic application
  • Conducted training for 35 maintenance personnel
  • Managed fire suppression and power distribution systems
  • Managed $1.3M sand reclamation installation project
  • Working closely with maintenance and production personnel to resolve equipment issues and reduce downtime
  • Performed maintenance procedures and repairs on existing electrical products and systems.
  • Inspected completed installations to observe operations and verify conformance to design and equipment specifications.
  • Successfully managed multiple projects simultaneously by setting clear goals, prioritizing tasks, and monitoring progress.
  • Provided technical support to colleagues on complex issues, assisting them in finding efficient solutions to problems.

Maintenance Electrician

TRW
10.1996 - 04.1997
  • PLC, HMI programming and troubleshooting all equipment electrical controls
  • Installed new equipment and modified existing equipment.
  • Reduced downtime by promptly troubleshooting and repairing electrical issues in industrial machinery.
  • Reviewed blueprints and schematics to properly place wires, fixtures and appliances.

Maintenance Electrician

Anchor Advanced Products
02.1992 - 10.1996
  • PLC, HMI programming and troubleshooting all equipment electrical controls
  • Installed new equipment and modified existing equipment.
  • Responded to fault and wiring issues, identifying hazards and problems.
  • Conducted preventive maintenance on equipment.
  • Reduced downtime by promptly troubleshooting and repairing electrical issues in industrial machinery.
  • Collaborated closely with other maintenance professionals to coordinate repairs efficiently without disrupting daily operations.
  • Improved equipment reliability by implementing preventive maintenance schedules and procedures.
  • Safely installed new electrical components, fixtures and motors in addition to testing systems to enhance power flow.

Electronic Technician

United States Air Force
09.1987 - 09.1991
  • Weather Equipment Specialist supporting all ground aircraft navigational systems and weather equipment
  • Gained recognition for excellent troubleshooting skills, often called upon to resolve complex issues and restore systems to optimal functionality.
  • Reduced downtime by proactively identifying potential failures in electronic systems and implementing preventive measures.

Education

Bachelor of Science - Engineering Technology, concentration in electronics

East Tennessee State University
Johnson City, TN
05.1999

Six Sigma Green Belt -

Breakthrough Management Group (BMG)
12.2007

Certificate in Electronics -

United States Air Force
Chanute AFB, IL
01.1988

Skills

  • Lean Manufacturing
  • Six Sigma
  • Project Management
  • Engineering & Maintenance Management
  • TPM
  • Safe Quality Foods (SQF)
  • Automation
  • Capital budgeting
  • Equipment installation
  • Project management
  • Manufacturing automation
  • Preventive maintenance
  • Reliability engineering
  • Team leadership
  • KPI tracking
  • Compliance auditing
  • Continuous improvement
  • Automation design

Certification

  • SMED Implementation, 01/01/02
  • Managing Multiple Project, 01/01/01
  • Banner/Turck, Sensor University, 01/01/99
  • Total Productive Maintenance Implementation, 01/01/99
  • Eight Disciplines of Problem Solving, 01/01/98
  • Cincinnati Milicron Maint. & Troubleshooting, 01/01/98
  • Personalysis Training, 01/01/98
  • Toyoda CNC Machinery Maintenance, 01/01/97
  • ABB Robotics, 01/01/96
  • Allen Bradley SLC 500 Programming, 01/01/94
  • Allen Bradley PLC-5 Programming, 01/01/94
  • Management Problems of a Technical Person, 01/01/94
  • Kepnor-Tregoe Troubleshooting, 01/01/93
  • Allen Bradley PLC-5 Maint/Troubleshooting, 01/01/92
  • Allen Bradley Panel View Programming, 01/01/92

Professional Training

  • Fanuc Robotics Electrical Training, 01/01/24
  • OSHA Equipment Guarding, 01/01/16
  • Milliken Safety Conference, 01/01/14
  • SolidWorks, 01/01/13
  • Statistical Process Control, 01/01/13
  • OSHA 30 Hour, 01/01/10
  • Kaizen facilitator, 01/01/07
  • Value Stream Mapping, 01/01/07
  • Principles of Lean Manufacturing, 01/01/07
  • SAP User Training, 01/01/07
  • World Class Maintenance, 01/01/05
  • Six Sigma Process Owner Training, 01/01/05
  • PM/PdM Implementation, 01/01/04
  • TS 16949 Auditor Training (Certified), 01/01/04
  • Strategic Maintenance Leadership, 01/01/03
  • Principles of Lean Manufacturing, 01/01/02

Affiliations

  • Society of Maintenance and Reliability Professionals

Timeline

Corporate Sr. Automation Engineer (Hybrid)

SIG
06.2019 - Current

Technical Manager (Engineering & Maintenance)

SIG
11.2008 - 06.2019

Engineering Manager

Gatorade
04.2008 - 11.2008

Engineering/Maintenance Manager

TAMKO Building Products
09.2004 - 04.2008

Maintenance Manager

Lear Corporation
10.1997 - 09.2004

Plant Electrical Engineer

Doehler-Jarvis
04.1997 - 10.1997

Maintenance Electrician

TRW
10.1996 - 04.1997

Maintenance Electrician

Anchor Advanced Products
02.1992 - 10.1996

Electronic Technician

United States Air Force
09.1987 - 09.1991

Six Sigma Green Belt -

Breakthrough Management Group (BMG)

Certificate in Electronics -

United States Air Force

Bachelor of Science - Engineering Technology, concentration in electronics

East Tennessee State University

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James C. Copenhaver