Levi Karhoff

• Lead powerhouse operations and reliability strategy for a 25-person team supporting critical utility systems in a 24/7 manufacturing environment.
• Direct safe and reliable operation of boilers, ammonia refrigeration systems, air/CO₂ compression, and cooling water systems supporting plant-wide production.
• Drive Process Safety Management (PSM) compliance, corrective actions, and risk mitigation to strengthen operational safety and system integrity.
• Spearhead Autonomous Operations (ATO) initiatives across key utility assets, improving operator ownership and equipment reliability.
• Lead root cause analysis and reliability engineering efforts to eliminate recurring failures and improve system uptime and efficiency.
• Delivered major boiler overhaul and maintenance strategy improvements, improving fuel efficiency by 8%.
• Engineered PLC/BMS control system improvements eliminating nuisance trips and improving operational stability.
• Optimized control strategies (PID tuning), reducing process variability and improving system performance.

• Led cross-functional continuous improvement and reliability initiatives across high-speed packaging operations, driving record performance results.
• Improved system performance and reliability through PLC programming, automation enhancements, and process optimization.
• Delivered major defect and loss reductions through process standardization and equipment optimization initiatives.
• Led multiple reliability-focused redesigns and maintenance strategy improvements that significantly reduced chronic equipment failures.
• Championed zone-level maintenance best practices adopted across multiple production areas.
• Supported packaging system upgrades and changeover improvements in collaboration with OEMs and technical partners.
• Evaluated system performance, identifying areas for improvement and recommending enhancements.

• Owned end-to-end performance, reliability, and strategic direction for high-speed production lines in a 24/7 manufacturing environment.
• Led cross-functional teams of operators, mechanics, electricians, and planners to drive operational excellence and accountability.
• Transformed underperforming assets using KPI management, root cause analysis, and maintenance optimization strategies.
• Managed maintenance planning, production scheduling alignment, and a $40K/month operating budget.
• Improved overall line performance, elevating assets from lowest-performing to top-tier within the network.
• Delivered rapid operational improvements, breaking multiple production records and achieving best-in-class performance metrics.
• Led successful introduction of new product/package formats with stable ramp-up and minimal production disruption.

• Supervised daily operations to ensure adherence to safety and quality standards.
• Led large-scale shift operations across multiple production lines in a high-volume manufacturing facility.
• Directed teams of supervisors, mechanics, electricians, and operators to ensure safety, quality, and production performance.
• Managed real-time operational decision-making, incident response, and production recovery activities.
• Enforced safety, environmental, and quality standards across multi-line operations.
• Drove performance accountability across shift teams to maintain throughput and reliability targets.

Jan 2017 – Oct 2018

• Led cross-functional teams to implement strategic initiatives and drive operational efficiency across multiple high-speed production lines in a 24/7 manufacturing environment.
• Supervised cross-functional teams of operators, mechanics, and electricians to ensure safe, reliable, and efficient production execution.
• Coordinated maintenance planning and execution across multi-shift mechanical and electrical teams, balancing preventive maintenance with production demands.
• Improved work order execution quality, planning accuracy, and maintenance compliance through standardization and process discipline.
• Developed and implemented maintenance procedures, KPI tracking systems, and reporting tools to improve operational visibility and performance management.
• Supported troubleshooting, quality control, backlog management, and parts optimization to improve equipment reliability and production stability.