Summary
Overview
Work History
Education
Skills
Accomplishments Achievements
Hiking, Snowshoeing, Kayaking
Timeline
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TERRANCE A. PISANELLI

Avon Lake,OH

Summary

Resourceful plant management leader with expertise in cost controls, lean manufacturing principles and employee training. 28-year track record of success in metals production.Team leader with excellent relationship building skills. Background in Continuous Improvement, Process Engineering, and Maintenance. Experience in large-scale startup projects and large-scale capital installations.

Overview

28
28
years of professional experience

Work History

Plant Manager

Materion Inc.
04.2022 - 01.2024
  • Managed all aspects of Lorain Foundry operation
  • Bottom line responsibility for achieving Safety, Environmental, Production Quality, and Financial goals
  • Maintained 0 injury rate
  • Reduced backlog.

Operations Manager

Materion Inc.
08.2018 - 04.2022
  • Accountable for all combined functions Strip and Bulk (Plate, Rod, Bar, Tube) manufacturing including Safety, Continuous Improvement, Quality, Production, and Maintenance
  • Champion capital investment and process improvements to increase production capacity
  • Develop budgets for all operational units
  • Ensure manpower is matched to demand
  • Successfully reorganized department safety and housekeeping to achieve a 0 OSHA injury rate as well as a $40,000 reduction in spend
  • Championed Safety improvements for our extrusion process that eliminated a longstanding safety concern
  • With the safety concern mitigated we removed the largest input barrier to our most constrained unit, preparing it for round-the-clock production.

Operations Manager

Materion Inc.
06.2015 - 08.2018
  • Managed Strip Operations including Safety, Quality, Production, and Maintenance
  • Champion capital investment and process improvements to increase production capacity
  • Develop budgets for all operational units
  • Ensure manpower is matched to demand
  • Saved $600,000 in quality scrap while improving productivity 7% via continuous improvement projects
  • Improved yields on most profitable alloy by 3% resulting in $750,000 in additional sales
  • Led team to address quality issues at our largest strip customer
  • Implemented employee development process within department for Process Engineers and supervisors.

Operations manager Cold Rolling

Cleveland Cliffs
01.2015 - 06.2015
  • Manage Daily Cold rolling operations for Finishing Division including Process Improvement, Safety, Cost, Quality, and Delivery for 250-person department.

Tandem Rolling Process Manager

Cleveland Cliffs
01.2009 - 01.2015
  • Managed Quality, Safety, Cost, Training, Yield, Scheduling, ISO & Environmental Compliance of 5-Stand Cold Rolling Mill with 40 hourly employees
  • Implemented 'operator maintenance', utilizing operational staff for lower skilled/lower-level tasks and allowing our maintenance workforce to fully utilize their skills
  • Developed rolling practices for new grades of Advanced High-Strength Steels used in light-weighting vehicles
  • Developed new crowing and roll force distributions for all mills
  • Worked with roll vendors to implement new texturing practices to improve feeding in high roll force situations.

Pickling Process Manager

Cleveland Cliffs
10.2003 - 12.2008
  • Managed day-to-day operation of HCl Acid Pickling Unit, responsibilities included: safety, training, personnel evaluation, leadership development, environmental compliance, yield improvement, and overall cost reduction
  • Project Manager for Cognex Surface Inspection System installation and startup
  • Project started up on-time and on-budget and was fully commissioned 6 months after startup
  • Improved productivity 8% at pickler though reliability improvements
  • Set new single day, weekly, and monthly production records.

Electronics Engineer

Cleveland Cliffs
04.2002 - 10.2003
  • Managed day-to-day operation and maintenance of electronics department, including all automation equipment, measurement gauges, quality systems, and electronic drives
  • Research and implement upgrades and equipment replacement to increase reliability of electronic equipment
  • Maintain all equipment certifications and quality standards according to ISO/TS 16949 guidelines.

Area Supervisor

LTV STEEL COMPANY
01.1999 - 01.2002
  • Planned long-term projects, managed day-to-day operations of electrical department, including supervising and training of 30 employees
  • Managed inventory and stock levels to achieve MRO reductions resulting in $200,000/yr annual savings
  • Developed annual maintenance plans; set departmental goals and spending targets to administer $4.3MM budget
  • Negotiate grievance settlement procedures with Union and Labor Relations officials
  • Work with union representatives to plan, evaluate, and instruct hourly technician training program.

Electrical Engineer

LTV STEEL COMPANY
01.1997 - 01.1999
  • Implemented SAP rollout for electrical department and managed $50,000 in computer equipment installations and upgrades for the project
  • Performed systems maintenance and programming; equipment specification and installation; and supervision of 7 hourly employees
  • Coordinated OEM implementation of LTV design during electrical upgrade of $5 million grinding system
  • Developed data acquisition and automated testing software for predictive maintenance program, reducing lost production time due to unplanned repair work by 5%
  • Designed MMI’s using Wonder Ware and Interact software while on planning and installation team for $10 million material handling system.

Management Trainee

LTV STEEL COMPANY
01.1996 - 01.1997
  • Completed Maintenance and Supervision training including Total Quality Management, Fluor Daniels predictive/preventive maintenance procedures, effective communications and presentations, and effective negotiation techniques
  • Maintained GE PLC's and software; programmed Avtron and Allen-Bradley Drives: installed and maintained control and communication networks; programmed using C++, and updated AutoCAD documentation for Hot Mill systems.

Education

Master of Business Administration – Finance -

Case Western Reserve University Weatherhead School of Management
Cleveland, Ohio
01.2000

Bachelor of Science - Electrical Engineering -

University of Cincinnati College of Engineering
Cincinnati, Ohio
01.1996

Skills

  • Lean Manufacturing Processes
  • Resource Coordination
  • Safety Management
  • Six Sigma Expertise
  • Team Building and Development
  • Project Management
  • Cost Control
  • Training Programs
  • Performance Improvements
  • Facilities Maintenance

Accomplishments Achievements

  • Green Belt trained
  • OSHA 10 certification

Hiking, Snowshoeing, Kayaking

I love the outdoors and the opportunity for contemplation the water and woods offer.  I enjoy hiking in any season, adding snowshoes when the weather dictates.  In the warmer months I can be found paddling a kayak upriver or in the waters along Lake Erie's coast

Timeline

Plant Manager

Materion Inc.
04.2022 - 01.2024

Operations Manager

Materion Inc.
08.2018 - 04.2022

Operations Manager

Materion Inc.
06.2015 - 08.2018

Operations manager Cold Rolling

Cleveland Cliffs
01.2015 - 06.2015

Tandem Rolling Process Manager

Cleveland Cliffs
01.2009 - 01.2015

Pickling Process Manager

Cleveland Cliffs
10.2003 - 12.2008

Electronics Engineer

Cleveland Cliffs
04.2002 - 10.2003

Area Supervisor

LTV STEEL COMPANY
01.1999 - 01.2002

Electrical Engineer

LTV STEEL COMPANY
01.1997 - 01.1999

Management Trainee

LTV STEEL COMPANY
01.1996 - 01.1997

Master of Business Administration – Finance -

Case Western Reserve University Weatherhead School of Management

Bachelor of Science - Electrical Engineering -

University of Cincinnati College of Engineering

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TERRANCE A. PISANELLI