Alan Ferrara
Maintenance & Reliability Superintendent at Cargill - Protein & Salt
Maintenance & Reliability Superintendent at Cargill - Protein & Salt
Proven skill set working with cross functional teams to develop and implement asset management strategies. Maintenance strategies provide cost saving that maximize maintenance budgets by way of improved mechanic and materials management. Over10 years as manager, supervisor and technician in the automotive and medical device industries. 
•	Strengths - people leadership, strong technical background and passion for Lean Manufacturing. 
•	Accomplishments - changing cultures from reactive to planned and scheduled, communication and mentoring staffs to improve facility layouts, process flow, cell technology, cycle time reduction, automation, capital justification, and material warehouse and asset management. 
•	People development - skills assessments, gap analysis, associate development, vacancy risk and knowledge transfer development.
Cargill - Protein & Salt
The Maintenance Superintendent is responsible for the continued implementation and leadership of maintenance and reliability strategy for the facility. 
Activities include:
•	Development, alignment & implementation of reliability excellence practices/strategy; proactive maintenance and repair; project planning, contractor/vendor management; 
•	Best practice application, training and support; and people management. This position is a key leader in creating and managing change in the organization as well as the operations management team.  
•	This position is responsible for driving the improvement of plant reliability-championing the continued move form reactive to proactive maintenance and applying knowledge and experience to ensure continuous improvement to optimize the company’s physical assets and maintenance and reliability processes and strategies. 
•	The incumbent will manage and further develop groups of people including exempt production supervisors.
Watkins Glen, NY
Maintenance & Reliability Superintendent
Seattle City Light. A department of the City of Seattle.
https://www.linkedin.com/company/seattle-city-light
Skagit Hydroelectric Project in Newhalem, WA. The Skagit Facilities Manager provides leadership for major maintenance, repair, warehouse/materials and fleet operations at the 840MW Skagit Hydroelectric Project. Responsible for a budget of approximately $10 million dollars for operations and maintenance expenditures, and staff of approximately 40 regular and 14 seasonal employees. 
JOB RESPONSIBILITIES:
•	Planning and Scheduling CIP and O&M work: materials management, resource allocation, contractor support, safety reviews and environmental reviews. 
•	Manage and supervise crews consisting of various trades and crafts: painters, plumbers, ground maintenance crews, warehousers /materials, store keepers, cooks, and camp service aides. 
•	Coordinate and oversee Skagit Tours, Skagit General Store, Gorge Inn and housing operations 
•	Manage and implement human resources policies and programs consistently, and in support of utility-wide practices to recognize diversity and commitment to race and social justice. 
1.Community/work place accomplishments: Over 15 million dollars Skagit Warehouse Material organization project. Project includes KPIs, centralization of spares for a 6 mile radius of remote locations.
2.Championed design of new exercise/weight room to improve employee morale, reduce strains, sprains, and other injuries. 
3.Coordinated implementation of town traffic flow and signage to reduce community/tourist vehicle accidents. The Skagit project can receive over 1,000 visitors per week driving about the town. 
4.Developed business case to replace and upgrade new Newhalem ADA accessible playground. Installed and enjoyed by local residents and visitors in 2016.
5.Provided Site leadership during the Goodell Creek Fire.
Newhalem, WA
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Maintenance Manager
Zimmer
https://www.linkedin.com/company/zimmerbiomet
Provides strategic leadership and oversight of Asset Management activities to minimize maintenance costs, improve reliability, and, reduce the un-scheduled down time of Zimmer production equipment.
Addition Responsibilities: Manage Maintenance Spare Department; Manage Installation Qualifications.
General Functions --
•Establishes and maintains the strategic direction for the maintenance program in Warsaw Operations following PAS-55/ ISO-55000 standards.
• Leads or participates in transformational projects for the Zimmer Ops organization: TPM, Asset Criticality Assessment, and Current State of asset portfolio for labor & materials costs, setting up department KPIs.
•Schedules and prioritizes operations and reacts to emergency situations as they arise and resolves them in an expeditious manner.
•Manages activities of maintenance personnel either directly or through subordinate supervisory team
•Manage activities of contract labor; electricians, plumbers, construction, and waste materials.
•Coordinate preventative maintenance activities to insure regulatory compliance. Set department KPIs.
•Manage all production machine validations for installations (IQ). 
•Technician development: skill assessment, gap analysis, development plans, vacancy    risk analysis.
•Manage Maintenance Spare Parts $5.8 million+ inventory. Established KPIs. Help develop vendor service contracts for assets.
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Manager, Maintenance Reliability
Johnson & Johnson Ortho Clinical Diagnostics, Inc
Provide supervision to ensure the effective maintenance of all equipment associated with the manufacturing activities within the Reagent Manufacturing site. Oversees daily activities of maintenance personnel and work to improve processes. Review/approve maintenance documentation such as preventive maintenance procedures, maintenance requests, calibration notifications.  Ensure timely completion of investigations within the maintenance group to support release of product on time.   This individual also oversees the operations of the central calibration functions in a manufacturing environment.   At this level the role has increased responsibility including, but not limited to, additional skills, multiple lines/products, leading cross-functional teams.  Oversee personnel work and vacation schedules to ensure proper manufacturing support.   Ensure 24/7 staff response and support is maintained.  Manage personnel development and resolve concerns, provide ongoing feedback and deliver performance evaluations.   Support manager in budget and cost reductions identification and implementation.
Rochester, New York Area
Maintenance Supervisor II
Johnson & Johnson
https://www.linkedin.com/company/johnson-&-johnson
Leadership
•	Collected information from maintenance staff and internal customers
•	Developed clear Team Leader expectations
•	 Set clear vision for maintenance department 
•	Applied specific, measurable, attainable, realistic and timely "SMART GOALS" for all maintenance teams
•	People skills-personable, mentoring/coaching, sensitive, and personable, servant style
•	Enjoy the dynamics of the 24/7manufacturing environment
Development
•	Green Belt Certification in process. My project is Improve Mean cycle time between interruptions for slide shorting and stacking for Gen 3 SAMs. Completed all class work with certifications.
Business Goals
•	Project Landscape/Monet: Rochester OCD Maintenance Team Leader.  Landscape, will identify points of leverage and areas of opportunity to drive improvement, and deliver long-term competitive advantage for Johnson & Johnson. Also will help to accelerate connections between the site and other MD&D teams and best practices.
•	Slide Assembly Machine Capacity Improvement: Lead maintenance activities in direct support of this project by applying OEE/ME2 processes & principles in Slide Manufacturing. With a multi team focused on improvements in availability, performance, and quality, our team was able to produce a virtual slide assembly machine to help meet customer demand and reduced back log.
•	Maintenance Apprentice Program: Obtained industry baseline, and assisted in development of first funded OCD maintenance apprentice program to address key knowledge transfer and vacancy risk issues within work force. 
•	Contributed in the strategic development of a new version of Maximo (CMMS system) for computerized maintenance management that has been adopted as the platform for Johnson & Johnson. The system is aimed at driving higher equipment reliability and uptime while improving efficiency in maintenance time utilization.
Rochester, New York Area
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Maintenance Supervisor I
Southco
https://www.linkedin.com/company/southco-inc-
Manage primary Stamping, Davenport, CNC areas and secondary operations up to 22 employees. Manage a highly diverse product class over three shifts. Ensure optimization of procedures and manage performance of value streams from production planning to finished product. 
• Utilize lean manufacturing methodology to improve processes from high inventory, batch manufacturing to a focused customer demand driven facility, increase on time to request to customers and reduce overall cost within the product class.

• Led multiple Kaizen, Kanban and other continuous improvement projects that reduced floor space, set-up time, materials, expenses, and increased efficiency and revenue.
o Consolidated gauges and tools needed for projects into each work center, organizing tool supply, increasing operator efficiency, and improving calibration.
o Reduced floor space by consolidating eight low-production work cells into one high-volume center. Implemented quick-change tooling, eliminating long set-up process.
o As Total Productive Maintenance Coordinator (TPM), completed 8 events, maximizing machine performance. 
o Mapped processes to reduce waste and operator footsteps.
o Led and participated on multiple Continuous Improvement Teams.
o Developed detailed operation and work-flow schemas to standardize employee performance.
• Analyze capacity and develop standardization via 5S to deliver high quality products at the lowest cost with minimum lead time.
• Develop process controls and monitor performance in compliance with established process and standards and to maximize resources.
• Developed and maintain methodology to track performance: safety incidents, PPM, first pass yield, quality, OEE, and employee data. Utilized expertise in Excel to design spreadsheets.
• Cross-trained employees, maximizing coverage and maintaining an empowered work culture. 
• Managed entire plant production for seven months (80 employees) while the supervisor was deployed to Mexico.
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Production Supervisor II
Southco
https://www.linkedin.com/company/southco-inc-
As a Senior Technician my responsibilities are to use advance knowledge of Southco’s manufacturing processes and problem solving techniques to implement cost effective solutions. The Senior Technician also performs general duties of technical jobs in several areas including the modification of primary and secondary operations of a facility, quality, maintenance and lean manufacturing. These are the five basic elements of the complex title of Senior Technician. 
•	Evaluate processes and equipment.
•	Work with Production Supervisors daily on process capabilities
•	Diagnoses and resolves operating difficulties throughout facility
•	Implement lean techniques
•	Create, issue and implement paper work for all processes
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Senior Technician
HAN-TEK, Inc.
https://www.linkedin.com/company/han-tek-inc.
Service technician, Overhead crane systems, Third party Osha Crane inspections, Conveyor systems, Systems automation
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Electrical
Valeo
https://www.linkedin.com/company/valeo
Blue Print reading, Mechanical, Electrical.  
•	Troubleshooting all types of process machinery.
•	Preventative maintenance, and cost savings on   machinery.
•	Electrical and mechanical machine building.
•	Installed power distribution systems.
•	Electrical Construction.
•	Hoists and Over Head Cranes
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Electrical
ITT hancock
Electrician
certificate
BLERA Program
•300+ hour program - meets Wednesday nights and all day Saturdays
•Cutting-edge training from experienced police professionals
•Curriculum includes: ◦Emergency response driving
◦Defensive tactics
◦Firearms,
◦Tactical communications
◦And much more
Basic Law Enforcement Reserve Academy
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Skagit Valley College
https://www.linkedin.com/school/skagit-valley-college/
Bachelor of Professional Studies.
Business
Empire State College of New York
Electro Mechanics
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Lansing Community College
https://www.linkedin.com/school/lansing-community-college/
RLTHomas HS
Green Belt Project: MRO Stores Vending Machine Usage Project.
Measure current free stores items and identify percent for a transition to a vending based solution. 
Project goals: floor space savings, inventory reduction 15%, Increased efficiency for MRO warehouse staff, Point of use of PPE and Tooling in cost centers.
Cargill
Cargill Lean Six Sigma GB Certification
The Hero Award was given to Seattle City Light Employees on the Skagit Hydro Project who helped during the Goodell Creek Fire in 2015. No injuries or structures were lost from the fire.
Seattle City Light
2016 Light, Power, Pride Award
Is your company ready for the unexpected? Hot topic speaker on the subject lessons learned from ICS Goodell Creek Fire. Subjects discussed: Does your company have an Incident Management Plan?  Has your leadership team been trained in ICS?  Does your company train and practice emergency scenarios?  Do you have equipment ready and employees who can set it up?
National Hydropower Assocition
Hot Topic Speaker
Launching a Successful TPM Initiative (Case Study 4)
 Alan A. Ferrara, Reliability Manager
 Zimmer Holdings

 How do you start a successful TPM/reliability initiative that will continue to develop stakeholders and save money? This case study will discuss tools used and lessons learned on how to change the culture of your business. Alan will share his perspective, from the operations floor to managing and implementation. You’ll see some great examples of how to engage the workforce and set up culture change. This session will cover: 1) The Reliability Vision—how to establish corporate goals, key performance indicators (KPIs), and, most importantly, communication strategies. 2) The Current State—analyzing your business using reports from computerized maintenance management systems (CMMS), technician head counts, skills assessment, gap analyses, development plans, and voice of the customer. 3) The Implementation Plan—how to develop and use criticality assessments and update your preventive/predictive maintenance plans, maintenance spare part strategies, and operator asset care programs to make them robust. 4) Standardization—defining roles and responsibilities, accurate job descriptions, and procedures and policies to standardize your program, as well as celebrating success.
Productivity Inc
Case Study Speaker at the TPM Experience Conference
Whatcom County Sheriff
With a vision of making Whatcom County the safest in the state through excellence in public safety, your Sheriff’s Office serves all the people who visit and reside in our community. As a reserve deputy sheriff I train and work 20 hours per month as a volunteer. It is a great way to help people in need, and work with some of the finest men and women I have ever met.
Reserve Deputy Sheriff
https://www.linkedin.com/in/jessica-reith-0189a8138
Mason City, IA
Jessica Reith
Plant General Manager at Cargill Protein
https://www.linkedin.com/in/aaron-robinson-787823bb
Hersey, MI
Aaron Robinson
Warehouse Supervisor at Cargill Salt
https://www.linkedin.com/in/gary-zych-2b919b9
Tucson, AZ
Gary Zych
Corporate Continuous Improvement Lead, Lean Six Sigma Black Belt Certified
https://www.linkedin.com/in/jacob-hewett-603a5b138
Hopkins, MN
Jacob Hewett
Manufacturing Excellence and Technology Manager at Cargill
https://www.linkedin.com/in/allan-warren-605a34103
Mayfield, KY
Allan Warren
ADM North America Milling Maintenance Engineer
https://www.linkedin.com/in/dirk-jones-b44152172
Wichita, Kansas Metropolitan Area
Dirk Jones
Vice President Protein Group Supply Chain at Cargill
https://www.linkedin.com/in/marie-delong-519b79144
Anoka, MN
Marie DeLong
Senior Food Scientist at Cargill
https://www.linkedin.com/in/tammy-kellum-7904426b
Oneida, NY
Tammy Kellum
manager at self unemployed
https://www.linkedin.com/in/daniel-harris-05b66824
United States
Daniel Harris
--
https://www.linkedin.com/in/anthony-madick-4974aa181
United States
Anthony Madick
Plumbing our ware house work
https://www.linkedin.com/in/neil-notermann-4737416a
United States
Neil Notermann
--
https://www.linkedin.com/in/cathy-folk-b3016724
Warsaw, IN
Cathy Folk
Manufacturing
https://www.linkedin.com/in/bam-bam-373026134
Esbon, KS
bam bam
lay-about at self-unemployed
https://www.linkedin.com/in/glenn-neumann-0b221a29
Windsor, MO
Glenn Neumann
self-unemployed
https://www.linkedin.com/in/mike-doran-5174272b
Rochester, IN
Mike Doran
Manufacturing Associate Director in charge of New Product Introductions for BESST at Zimmer Biomet
https://www.linkedin.com/in/carrie-piggott
Warsaw, IN
Carrie Piggott
Account Manager at Patent Awards
https://www.linkedin.com/in/kayla-cook-bb0b4b7a
Fort Campbell North, KY
Kayla Cook
CEO at Gainfully self unemployed
https://www.linkedin.com/in/rick-larson-11922b33
Canon City, CO
Rick Larson
Owner, Self unemployed
https://www.linkedin.com/in/pam-bailey-544a7a13
Mechanicsburg, PA
Pam Bailey
Continuous Improvement Lead at Cargill Protein
Greg Clarke
      
          



            
              
        
              
  

    
        I had the pleasure of working with Alan as a member of the local leadership team at Cargill's Watkins Glen, NY facility. Al has both solid trade and leadership skills. He is people focused and has a passion for Maintenance & Reliability. He communicates well, applies DMAIC tools/techniques and leads by example. While at Cargill - Watkins Glen, Al was able to breakdown barriers and conflicts between the Production and Maintenance Teams. Removal of these conflicts and barriers resulted in better communication, sharing of ideas, stronger teamwork, respect for each other and several outstanding results in machine uptime, productivity, improved safety and ergonomic conditions.  I wish Al and his follow team members good health and continued success. I am confident that Al's leadership and work experience will enable the Cargill Team in Watkins Glen to continue to improve. Best regards! Andrew Lu
      
          



            
              
        
              
  

    
        Al is a great guy and easy person to work with.  He has a very difficult job, yet has always been a pleasure to work with.
Liked by Alan Ferrara
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Well, the time has come to put away my multimeter... Tomorrow is my last day of "work". Going to retire after working in Industrial…
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Inspire Improv and Coaching Inc is having a snow day :) Catch you Monday! #funfriday #snowday #emoyeeretention
Liked by Alan Ferrara
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When a municipal transportation authority replaced old buses, they worried about maintenance workers who had to climb atop the new buses. With four…
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Mexico
Alan Ferrara
Planning and Conversion Manager
https://www.linkedin.com/in/alan-ferrara-51154613
Farmington, MI
Alan Ferrara
Retired
https://it.linkedin.com/in/alan-ferrara-81501520
Bolzano
Alan Ferrara
Technical Support Specialist at Misuratori Fiscali Carlo Bocchio
https://www.linkedin.com/in/alan-ferrara-77a3582b
Boston, MA
Alan Ferrara
Regional Vice President at Fidelity Investments
Business Industrial Network - Engineers, Electricians, Mechanics, Maintenance WELCOME.
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TPM-LEAN HISPANO
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Automation & Control Engineering
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https://www.linkedin.com/groups/1967039
Kaizen (Continuous Improvement) Experts
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https://www.linkedin.com/groups/47831
The IAM Discussion Group
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Zimmer Biomet Alumni
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https://www.linkedin.com/groups/155925
Asset Management Strategy & Planning
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https://www.linkedin.com/groups/3726801
Association of Asset Management Professionals - AMP
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The Maintenance Excellence Institute
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https://www.linkedin.com/groups/2169725
CMMS, Facility Managers, and Technicians
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Rochester NY Residents
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