1. ROBERT MARCUS
132 West Alna Rd., Wiscasset ME 04578 marcusmtn@roadrunner.com 207-882-9514
SENIOR PROJECT / PROCESS / MANUFACTURING ENGINEER
Results driven Mechanical Engineer with a proven record of production and process improvements with an emphasis on safety, cost
reduction and implementation of Lean principles. Extensive knowledge of material handling equipment, blending and packaging
systems, tanks, pumps and piping systems, food grade manufacturing standards, process ventilation and electro-mechanical
equipment. Accomplished project manager responsible for complex capital projects with up to $750,000 in spending. Qualified PHA
leader. Acknowledged strengths in effective project management, problem solving, communication and documentation skills.
Recognized for dynamic, hands on engineering style, positive attitude and strong work ethic with the ability to multi-task and maintain
a high level of quality deliverables.
AREAS OF EXPERTISE
• Project Management
• Lean Manufacturing
• ISO Standards
• Project Documentation
• Process Safety
• SPC
• OEE Analysis
• Process Documentation
• Manufacturing Support
• HACCP
• Management of Change
• GMP Standards
PROFESSIONAL EXPERIENCE
Elmet Technologies LLC 2015 – Present
Sr. Product Engineer
Fully integrated manufacturer of molybdenum and tungsten products used in a wide range of industries and applications.
Hands-On Senior Product Engineer responsible for production and process improvements. LEAN implementation and Capital Project
Engineering to support the needs and goals of the manufacturing facility.
UTC Fire & Security, Pittsfield, ME. 2011 – 2015
Manufacturing Engineer
Fortune 500 Manufacturer of Fire Alarm Systems and Devices, Audible and Visual Signaling Equipment.
Manufacturing Engineer responsible for all aspects of the manufacturing process for eighteen electro-mechanical process lines, a
powder coat operation and wire leads/assemblies. This includes safety, ergonomic improvements, process capability, production flow
and arrangement, production optimization and work instructions. Lead role in Lean efforts and process improvements to reduce cost
and increase profitability. Team member in Operations that is responsible for developing the processes for Manufacturing, Quality
Control, Regulatory Compliance and Planning. Lead resource for the creation and implementation of new or improved manufacturing
processes.
• Completed two Kaizen events to redesign manufacturing cell layouts in order to improve productivity and streamline process
flow. Improved general arrangement resulted in a 15% increase in cell output.
• Led the Root Cause Analysis to improve the manufacturability of our Explosion-Proof Horn equipment. Efforts resulted in
the increased First Pass yield from 50% to 95%.
• Completed ACE Associate Certificate (LEAN Manufacturing training) within my first 11 months at UTC.
• Championed the Root Cause Analysis effort to resolve a manufacturing defect which was causing field failures of our Duct
Based detection system. Work resulted in eliminating field failures of the detector housing.
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2. ROBERT MARCUS
132 West Alna Rd., Wiscasset ME 04578 marcusmtn@roadrunner.com 207-882-9514
• Investigated the root cause of the UL test failures of our Push Button manufacturing process. Efforts resulted in resumed
manufacturing with minimal downtime.
FMC BIOPOLYMER, Rockland, ME 1991 - 2010
Food ingredient division of Fortune 500 Company. Manufacturer of Carrageenan (an extract from seaweed). Process includes both
wet and dry material handling, various filtration processes, drying/grinding equipment and a complete blending and packaging facility.
Senior Project / Process Engineer
Led capital projects from conception to completion. Included design, estimating, detailing, constructing, and implementation at the
Rockland Facility. Executed large projects including proposal preparation, project costs containment, coordinating and supervising
contractors, engineers and maintenance technicians, preparing project schedules and monitoring project performance. Lead process
support for the Plants’ food grade powder applications. Known by name as the blending, packaging, material handling, dust collection
and explosion venting requirements expert throughout the facility.
• Championed a multi-year effort to design an enhanced blending and packaging facility. Resulting design automated all
critical tasks, doubled capacity and reduced manpower requirements by 50%. Proposal had a projected savings of over $1M
annually based on an estimated cost of $2.5M.
• Managed the $3.5M capital plan for the Rockland Facility. Efforts resulted in annual capital plans that were within 1 to 3
percent of their targets for a period of 3 consecutive years.
• Significantly improved the operational performance of the blending and packaging process areas utilizing a team approach to
problem solving. Implemented OEE (Overall Equipment Effectiveness) measurements to verify performance.
• Cited by environmental auditors as an example of ‘Best Practice’ for my work in insuring the proper installation, protection
and signage of chemical storage buildings throughout the facility. Reduced material handling requirements by 50%.
• Received a pay grade promotion in 2002 in recognition of expertise in the grinding, blending and packaging systems.
• Orchestrated a successful transition from a drum based packaging line to a box based line that reduced packaging costs by
63%. Project included automated and semi-automated equipment to erect, fill, transport and seal the box contents.
• Recognized for project excellence in the development and installation of a process pH control system consisting of a bulk
tank, redundant pH measurements and controls as well as pumping and filtering systems. Project resulted in improved Plant
performance worth approximately $200,000/yr and another $150,000/yr. in Plant efficiencies. Project was completed below
budget and ahead of schedule.
• Led a Plant-wide dust explosion hazard assessment project which resulted in full compliance with OSHA standards.
• Noted by Managers for superior documentation of project files, BOM’s, PM’s and benchmark work orders.
• Delivered operational efficiency improvements through the following efforts.
o Improved standard grinding rates by 20% utilizing modified process techniques without incurring any capital costs.
o Increased the capacity of the on-line fine grinding process by 25% through operational changes. This significantly
reduced the off-line fine grinding requirements to better meet customer order timelines.
o Enhanced the visibility of the Plants’ operational efficiency through the implementation of revised tracking and
reporting methods.
o Revised the Change Request System for process and equipment issues. System upgrades increased operator
participation by 200%.
o Responsible for completing over 35 Change Requests per year over a ten year period.
• Key dry-end resource for Management and Plant personnel. Effectively resolved equipment and process issues in the
grinding, blending and packaging operations.
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3. ROBERT MARCUS
132 West Alna Rd., Wiscasset ME 04578 marcusmtn@roadrunner.com 207-882-9514
• Member of the Plant Safety Committee with responsibilities for the assessment and resolution of incident investigations
within the facility. Successfully corrected over 60 safety issues during my 12 year term on the committee.
• Eliminated operator exposure and increased system reliability within the waste process stream through the design and
installation of a bulk sulfuric acid tank and delivery system.
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4. ROBERT MARCUS
132 West Alna Rd., Wiscasset ME 04578 marcusmtn@roadrunner.com 207-882-9514
• Project manager and lead designer/developer for the following efforts:
o Bulk lime addition system that incorporated new conveyor technology and allowed for the stabilizing of the waste
stream process and the elimination of ergonomic issues.
o Super sack unloading systems that transferred product from super sacks to totes as well as sift the contents for ultra
fine contaminates.
o Saved $15,000 annually through the installation of innovative valve applications that eliminated wear.
o Significantly reduced ergonomic risk by designing a custom test stand for maintenance personnel to validate disc
jack functionality.
o Received praise from upper management for achieving noticeable reductions in processing costs by creating a
specialty blending area to process small batch orders and test material. Assessed system requirements and quickly
resolved issues to deliver process within an aggressive implementation schedule.
R.F. Richards Corporation, Worcester, MA 1989 – 1991
Staff Engineer/Production Manager
Wolverine Corporation, Merrimac, MA 1988 - 1989
Project Engineer
United States Gypsum Company, Charlestown, MA 1985 - 1988
Plant/Project Engineer
BASF Systems Corporation, Bedford, MA 1984 - 1985
Associate Quality Control Engineer
Teknor Apex Company, Pawtucket, RI 1980 - 1984
Quality Control Technician (summer intern)
EDUCATION
University of Rhode Island 1984
Bachelor of Science, Mechanical Engineering
PROFESSIONAL DEVELOPMENT
Good Manufacturing Practices for the Food Industry, Time Management, Questimate/Microsoft Project, Elements of Applied Process
Engineering, FMC Small Project Execution, FMC Project Management and Project Control, Process Hazard Analysis Leader
Training, Process Safety Management Training, Mechanical Integrity Training, ASME Code and Pressure Relief Valve Sizing and
Selection, Gould’s Pump Sizing and Selection Seminar, Negotiating Skills Seminar, Facilitation & Presentation Skills, Harley-
Davidson SQC Certification, Kaizen Principles, Lean Manufacturing, Value Stream Mapping, Relentless Root Cause Analysis.
AFFILIATIONS, HOBBIES AND AWARDS
Eagle Scout – 1980 Cub Scout Leader Boy Scout Leader Eagle Scout Mentor
Wiscasset High School Booster Club Wiscasset Recreation Volunteer Coach, Wiscasset Rec Coach of the Year – 2006,
Wiscasset Snowmobile Club Treasurer/Secretary Sound/Light Engineer for The Dyer Neck Gang
Snowmobiling, Stock Car Racing, Camping, Woodworking.
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