Kabiru Rufai

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• Developed and implemented production processes to increase efficiency and reduce costs through collaboration with operations engineers and Production team group
• Identified opportunity for off-spec reduction through process change, process optimization, and cost-saving opportunity in off-spec creation and plant shutdown.
• Served as manufacturing technical manager for a capital project, provided scope development and justification for the project, initiated MOC, worked with the Project Manager on timely delivery of the project, initiated PSSR with required personnel, and sought approval from the Director before start-up.
• · Lead emulsion filtration improvement effort of Self Cleaning Filter l with collaboration with BASF Charlotte Technical expert. This resulted in an 85% improvement in filtration performance, improved operation team efficiency, and cost saving of $350k/year.
• Lead improvement efforts in SGO Blend, back off spec trailer reduction by coordination with Shift lead and Quality for blend back opportunity. Track blend back consumption for effective improvement.
• Lead Improvement effort in digitalization of blend back into production process with input from Operation shift Lead on best method for process improvement.
• Lead Resin Utility and waste reduction improvement in waste generated, best cost-saving opportunity.
• Supported BASF NA PSM/RMP/RCMS as an Engineer Auditor with a review of critical elements: process safety review, MOC, PSSR, SIS, PHA, and PSI.
• Identified opportunities to improve product quality by collaborating with lab personnel on trial testing, NCM investigation, and FTQ quality improvement.
• Served as Auditor for Wyandotte Resin ISO, RCMS, PSM/RMP/RC Audit, RC management systems, and participated in EHS policy on plant weekly walkthrough, Safety Contact, live permit Audit, and incident investigation.

• Monitored operations on a daily/weekly basis and analyzed and studied trends to determine patterns, research inefficiencies, and identify action plans to correct issues.
• Provide hands-on support for the operation supervisor in process plant troubleshooting, PSM/OSHA/TCEQ, and emission-related issues.
• Provided guidelines and strategies in reducing off-spec creation and minimizing the creation of off-spec in the first place during the production process. Worked with the supervisor on product changeover, start recipe adjustment, to reduce off-spec creation.
• Designed dashboard overview for effective tracking KPI using OSI PI Vision, PI Explorer, PI Datalinks for process analysis and tracking of process improvement and emission monitoring, and production yield across the reactors for efficiency performance.
• Successfully optimized and reduced cycle time in all reactors, tracked and improved yield, reduced operating cost, and tracked quality improvement using statistical software such as Minitab to capture progress.
• Served as a role model and championed risk reduction activities for all plant employees by setting a Zero Incident mindset, as well as performing daily observations on safe work practices, compliance with basic rules, and setting high standards for housekeeping.
• Lead root cause analysis studies to resolve plant process upset and equipment-related malfunctioning.
• Lead continuous improvement Initiative using lean six sigma ideas with emphasis on process improvement, waste reduction and lost time reduction
• Lead root cause investigation to resolve plant process upset Like emission upset, quality challenge,cusomer complaint and equipment related malfunctioning. Developed engineering strategy to control the problem
• Lead the coordination, completion, and documentation of PSSR / MOC reviews to meet process safety and environmental standard.
• Developed and implementing process improvement plans that will enhance safety, quality, plant reliability, cost, and efficiency
• Served as SME and Technical manager for commissioning of thermal oxidizer incompliance with EPA regulation, developed SOP, technical information for operation teams

• Supervised team of 4 technicians , delivering mentoring, continuous training, and guidance in job challenges for customers on time delivery of slurry chemical to well site
• Assisted manager by implementing new policies and training entire team on latest procedures and customer requests.
• Implemented continuous process improvements, resulting in customer/business great success
• Maintained accurate records for tracking progress and performance of team members.
• Provided training and guidance to team members on operational procedures and best practices. Updated the procedure with final approval from the manager.

• Conducted laboratory experiments to evaluate the efficacy of various compounds in a range of applications for oil well fluid monitoring and thickening
• Collaborated with other researchers from different departments within the organization to develop more effective strategies for conducting experiments.
• Assessed customer requirements to develop customized solutions slurry solution that best meet their needs.
• · Lead and monitored additives formulation reactions and conduct associated analytics research on surfactant / polymer performance on mud-spacer.
• Lead polymer rheology improvement efforts in Pilot plant with emphasis on customer focus

• Optimized plant operations to maximize efficiency, reduced costs, and improved overall plant performance. Monitored and analyzed production data to identify areas for improvement and implementing corrective actions.
• Providing process improvements and participating in plant start-up, process troubleshooting, and optimization related to improve efficiency, capability, and safety. Interface with operations to provide technical support and recommendations on methods and improvements to eliminate problems.
• Developed and implemented process safety management systems PSM/OSHA regulation for the plant.
• Performed data analysis of process operations to identify improvement opportunities.
• Evaluated project proposals for cost effectiveness and impact on overall manufacturing objectives.
• Conducted root cause analyses for complex problems occurring in the refinery units
• Supported capital project with equipment design,sizing,P&ID update and review, cost estimate for the project's development and justification analysis, construction and installation supervision, construction walk-downs, start-up, commissioning, and documentation
• Provided technical expertise related to equipment operations / repairs and during units' turn around (includes vessel inspection, plant shut down / decontamination, EIP / confined space inspection development with details instruction. Optimizing plant operations to maximize efficiency, reduce costs, and improve overall plant performance. Monitoring and analyzing production data to identify areas for improvement and implementing corrective actions.
• Ensuring compliance with all safety regulations and promoting a culture of safety within the plant.
• Ensured compliance with all safety regulations and promoted a culture of safety among operators.