Vaughn P. Lancaster

Adept at driving significant operational improvements and cost savings, my tenure at VP Lancaster LLC and other leading firms showcases a track record of spearheading initiatives that resulted in over $16 million in savings and a 24% OEE increase. Expert in Lean Problem Solving and adept in bilingual communication, I excel in transforming maintenance processes and enhancing team performance.

Certified Maintenance and Reliability Professional, Society of Maintenance and Reliability

• Goodwill Volunteer
• Golf Coast blood donor
• Youth mentoring and coaching

• Independent Management Consultant, VP Lancaster LLC, Provides profitable, creative solutions and spearheads initiatives to improve: Maintenance processes, Asset management, Supervisor performance, reduction of costs, and address inefficiencies in mining, chemicals, heavy/light manufacturing, and management operating systems. Notable accomplishment: Total savings of over $16 million in additional throughput with no additional labor.
• Direct Report to VP of Engineering and Reliability, City Brewery, Led start up project of new plant in Latrobe, PA. Developed a complete PM program from ground up for all critical equipment with BOMs, Task Lists, and implemented into the client CMMS. Developed spare parts, consumables, inventory management strategy.
• Outage Management SME, Proudfoot, Worked with local managers to create a Maintenance Outage strategy to improve communication between schedulers and execution supervisors in the Extraction area; created a dedicated break-in crew. Result was 40% productivity improvement of time on tools.
• Senior Business Analyst, Implementation Engineers, Installed Maintenance Best Practices across three major chemical plants. Improved turnarounds, outage process and reduced the overall budgeted spend by $1,300,000 by prioritizing the work scope, instituting better controls to ensure an effective and efficient Turnaround. Also captured and installed lubrication routes in SAP that will result in availability improvement of 5%.
• Continuous Improvement Agent, Kainos Capital, Working at various CPG facilities owned by a Private Equity Firm to facilitate production improvements in OEE, Maintenance, Organizational Design, and Employee morale. Plants averaged increase in OEE by 24% which helped the firm sell three different companies for substantial profit gains.
• Production/Maintenance Workstream Lead, X/Celerant Consulting, Alleviated top causes for capacity erosion and production loss for Grace Chemicals, and implemented a Maintenance MCRS for two of Grace’s five chemical plants at the flagship Baltimore yard. Notable accomplishment: Attained a targeted annualized savings of over $12 million by increasing throughput, improving uptime, and reducing maintenance failures without adding labor hours.
• Maintenance Workstream Lead, Myrtle Consulting, Responsible for team of 15 subject matter experts to improve maintenance, planning, and scheduling across six lines for AB InBev at its Corona/Modelo plant in Mexico City. Integrated maintenance and production through effective cross-functional coordination and prioritization meetings. Notable accomplishment: Enhanced productivity by 17% by reducing mechanical downtime and improving equipment reliability and schedule attainment shutdown days.
• Manager, Americas Management Consulting, Hitachi Consulting, Engineered an integrated planning methodology and maintenance management system for the Potash Corporation of Saskatchewan – Phosphate Division, one of the largest combined mine and chemical facilities in the world. Notable accomplishments: Maximized ore stockpile by over 150%, schedule attainment by 23%, and PM attainment by 17%.
• Senior Project Manager, USC Consulting Group, Increased productivity through operations and supply chain process improvements for national and global organizations, including Luminant, Stillwater Mining in Montana, AngloGold Ashanti, Arcelor Mittal, Molycorp, Intrepid Potash, Goldcorp, PCS. Notable accomplishments: Realized $13 million in increased throughput for Luminant coal mines by enacting SIC (short-interval controls), supervisor training and tools, MOS, improved CMMS utilization, and targeted KPIs.

Has guided cross-functional, highly-collaborative teams in providing multi-million-dollar solutions for domestic and international industries and companies including Suncor, PCS, Luminant, Anglo Gold Ashanti, Arcelor Mittal, Molycorp, Intrepid Potash, Stillwater platinum mining, Goldcorp, Tyson Foods, Ab InBev, PCS, Devon Energy, NOV, McDermott International, Stepan Chemicals, Grace Chemicals, CHC Helicopter, Bombardier, and Cott Beverage.