RANDALL D.

ALLEY
1330 Bluffs Circle, Dunedin, FL 34698
727.215.3669
ra10a7036@westpost.net
-- ENGINEERING/PROJECT MANAGER --
SENIOR-LEVEL PROJECT MANAGER/ PROCESS ENGINEER who drives full-cycle initiatives
for new process/product development and industrialization. Capitalizes on alter
natives for cost/time savings, production excellence, and high quality. 15+ year
s experience managing projects and people. Steers teams to world-class performan
ce and builds cross-functional relationships.
TECHNICAL LEADER focused on process development, optimization, and engineering.
Uses leadership and technical expertise to uncover viable options and improve th
e speed of technical development. Instrumental at improving the R&D to industria
lization process, such as improved capacity, cost savings and/or process improve
ments. Delivers continuous enhancements and troubleshoots issues through design
of experiments (DOE) and statistical methods. Enjoys the challenge of new techno
logy and new ideas to make measurable improvements.
ADEPT PROJECT MANAGEMENT LEADER with strong problem-solving skills and methodolo
gy. Develops precise schedules and timelines, plans for success, and tracks prog
ress. Exceptional attention to detail for team's budget and financial management
(OPex and CAPex). Shows excellent judgment in decision-making and prioritizing.
Expertise in Microsoft Project, Excel, PowerPoint, and Gantt charts.
SKILLED TEAM LEADER AND TRAINER: manages people and team relationships to suppor
t corporate objectives and innovation. Displays maturity in the leadership and d
evelopment of team. Experienced in interviewing, hiring, coaching, training and
providing feedback to diverse employees. Known for being approachable by plant m
anagers and manufacturing employees; strives to create a clean line of communica
tion between R&D, Engineering, suppliers and the plants. Global leadership train
ing and international travel /projects have resulted in adaptability and sensiti
vity to cultural and social differences.

-- CAREER OVERVIEW --
ESSILOR OF AMERICA, INC (1990-PRESENT)
FILMS DEVELOPMENT MANAGER - DEI-NA Group [2007-Present]
Heads 5-person team of mid-level process engineers, process technicians, senior-
level engineers and/or interns, plus up to 9 indirect reports belonging to pilot
team. Managed up to $1.6M OPEX and $300K CAPEX project budgets. Advises other U
S and non-US manufacturing sites. Drives process-related and industrialization p
rojects and troubleshooting via DOE/statistical solutions.
* Manage Class-1 polarized lens process industrialization project for parallel n
ew process development in line with engineering industrialization; partnering wi
th R&D to eliminate development issues as well as coordinating efforts with exte
rnal companies for creation of new spin coating machine and thermoforming machin
e.
* Directed BST carriers cost reduction initiative preparing for a process roll-o
ut in Asia; nominated for Best Industrial Project.
* Boosted spin coater capacity 30% and exceeded yield goals with 5% improvement
by eliminating process shortfalls and decreasing cycle time of third-party equip
ment; nominated for "Mass Production Expertise" Award.
* Instituted cost-efficient BST carriers packaging: worked with external materia
l company to design sealed, recyclable packaging and select materials to meet mo
isture/air requirements and prolong shelf life. Procured tray packaging sealing
machine for in-house modifications, and calculated potential 60% cost reduction
equal to $330K in annual savings.
* Appointed as interim manager of engineering team in Mexico for 6 months, coord
inating work flow as well as providing training in time tracking software, ISO-c
ompliant quality system management documentation, and monthly reporting.
* Led test project for supplying BST carriers to 15 Lenscrafters stores, with $6
00K operating budget.
* Completed on-site testing of process at film supplier location in South Korea
to resolve film adhesion issue.
* Assessed inefficiencies of spin coating process in France, recommended yield a
nd output improvements.
* Headed polarized wafer thermoforming project, creating industrial process for
0.2mm TAC/PVA/TAC wafers; process was selected over R&D group's process due to w
afer quality consistency, radius stability, color, haze levels, and cosmetics.
COATINGS TEAM MANAGER - US Engineering Group [2005-2007]
Directed 5-person team comprised of senior mechanical engineer, 2 mid-level proc
ess engineers, and a process technician through projects and plant support to si
tes in Massachusetts, Pennsylvania, Mexico, Puerto Rico, and France. Managed $60
0K-$1.6M OPEX budget and up to $1.5M CAPEX budget. Defined annual goals and cond
ucted performance reviews. Oversaw dip and spin lens coating and blending proces
ses including troubleshooting and SOP writing/training. Handled purchasing and d
ocumentation such as monthly reports, team time and project tracking, and qualit
y documentation. Appointed to company's Wet Coating Chemical Technical Community
to provide advice and support enterprise-wide teams on global level.
* Assigned as Project Manager for BST Carrier Industrialization, a multi-million
dollar project to industrialize new coating process/technology from R&D. Presen
ted status reports to Business Team.
* Formed pilot team with supervisor and 9 technicians/operators; created 3,000 s
q. ft. pilot production area. Purchased all equipment including building of new
Spin Coaters.
* Received Essilor Global Engineering "Best Industrial Project" for BST Carrier
Industrialization project. Global yield exceeded target by 5% and project was on
-budget and within planned schedule.
* Led industrialization of new coating liquid from R&D and to be used in Essilor
Labs. Coating blending equipment built with minimal $15K investment and blendin
g process installed at Massachusetts plant. New coating replaced very expensive
coating liquid from external supplier for $900K savings/year.
* Interfaced with external company in the full-phase design and development of 2
robotic spin coating machines to improve performance, achieving Essilor Global
Engineering "Mass Production Expertise" Award in 2006.
* Partnered with finance to conduct BST carriers cost analyst, determining key c
ost factors impacting unit costs as well as devising action plan to reduce costs
; presented recommendations and received management approval.
* Audited blending process for Massachusetts plant, compiling recommendation rep
ort; appointed as instructor for company's technical training CD regarding hardc
oating blending, applications, and products.
COATING EXPERTISE LEADER - US Engineering Group [2003-2005]
Supervised 4-person team, including senior mechanical engineer, mid-level chemic
al engineer, and process technicians, through project completion and site suppor
t in Mexico, France, and the US including Puerto Rico. Held accountability for d
ip and spin lens coating and blending processes such as problem resolution, docu
mentation, and training. Contributed to new product development in collaboration
with R&D team. Contributed to Essilor Global Leadership Training.
* Drove process/equipment transfer for coating blending from Florida to Massachu
setts, completing efforts on time and within budget including validation, seamle
ss scale-ups, equipment installation/testing, training, and client interfacing.
* Integral role in developing new-hire hardcoating technical training manual tha
t provided insight on all components of coating lenses including raw materials,
blending, lens cleaning, preparation, machine operation, and testing.
* Assumed role as technical leader for design of spin coating machine for heat-c
ured and UV-cured coatings, completing $20K study with comparative analysis and
defining $300K in budget needs for robotic spin coater.
* Oversaw design, build-out, validation, and roll-out of Altius coating maturati
on/aging system, doubling capacity and cutting $180K in costs for Massachusetts
location; additional systems projected for roll-out in 2011.
SENIOR COATING ENGINEER - US Engineering Group [2001-2003]
Handled process engineering and troubleshooting for dip, spin, and in-mold coati
ng and blending processes; managed 2 technicians. Compiled and updated SOPs for
lens cleaning and coating processes, training production teams on changes. Colla
borated with R&D engineers in development of new processes and products. Support
ed manufacturing operations in Massachusetts, Pennsylvania, Mexico, Puerto Rico,
and France.
* Collaborated with Team as Lead Coating Process Engineer on installation of mil
lion-dollar coating blending process. Project provided improvement of coating bl
ending and transferred coatings from France to Florida.
Goal was to supply US-based customers, reduce shipping costs and shipping proble
ms associated with flammable liquids, and remove air freight requirements due to
temperature sensitivity and limited shelf-life.
* Transferred Altius M coating blending from France to Florida to provide on-han
d supply for 15 North American customers while containing shipping costs; cut $7
0K in expenses by introducing lower-cost coating maturation process and equipmen
t.
* Elevated yields ~3% for polycarbonate lens coating process by overseeing US ph
ase of global project to replace NTPC coating with NTPC2; handled validations an
d scale-ups in Florida, Massachusetts, and Pennsylvania.
* Prototyped automated continuous polycarbonate lens spin coating process to red
uce production from 6-hour batch process to 90 minutes as well as lower labor an
d unit costs via idle spin coating and coating curing equipment.
* Developed dip-coating process for new product requested by Marketing involving
Polycarbonate Bi-focals lenses using NTPC2 coating and new process implemented
at Carbondale, PA plant with product launched on time.
COATING PROCESS ENGINEER II - Engineering Group [1996-2001]
Completed coating process training at different sites to transfer knowledge and
startup process for Florida location. Delivered daily engineering support to pol
ycarbonate lens and coating production area, which was recognized as "Best in Cl
ass"" for performance and yields.
* Partnered with production and engineering teams in developing, validating, and
launching multimillion-dollar polycarbonate lens injection molding and dip-coat
ing production; assumed lead role for installation of dip-coating component, out
performing yield objectives 10% and boosted machine capacity 20% via cycle time
improvement.
* Steered C-98 coating blending and lens coating process transfer from Florida t
o Mexico for FSV Thin & Lite lens, reaching yield/volume goals and cutting produ
ct costs; nominated for "Best Original Design/Solution" Award.
* Delivered $100K+ cost savings and doubled production volume by proposing polyc
arbonate lens coating process design change to expand machine usage capacity and
floor space.
* Lowered daily water consumption 20% by instituting water cascade system in rin
se water tanks for lens coating as well as engineered and instituted reservoir t
anks to control viscosity and coating thickness for final product.
* Played key role in starting up automated lens production/coating process, lead
ing spin coating phase to contain unit costs by lifting yields and improved bi-f
ocal lens coating.
* Two-time recipient of Essilor Engineering Excellence "Technology" Award for pr
ocess engineering improvements and support for polycarbonate coating.
* Completed 2-week training in France, preparing documentation for coating react
or blending process transfer to Florida.
COATING PROCESS ENGINEER I - Engineering Group [1990-1995]
Monitored lens dip and in-mold coating processes as well as coating blending pro
cesses, applying DOE and statistical methods to resolve errors. Provided on-site
support to manufacturing locations in Mexico, Puerto Rico, and Thailand.
* Directed company's first coating process transfer to Mexico, handling staff tr
aining in all stages including coating, blending, testing, lens cleaning, and ma
chine operation; completed 1 month ahead of time and achieved yield targets, rec
eiving nomination for Essilor "CQI Silver" Award in 1995.
* Delivered comprehensive startup support for TS56-T coating process in Thailand
. Completed documentation, SOP and facilitated staff training to initiate produc
tion of new coated lens product.
* Selected to observe, analyze, and document Canadian process in order to develo
p coating process for operation in Brazil.
* Handled validation testing for new in-mold release coating lots to ensure dail
y production continuity with zero downtime, sustain coated lens volumes, and avo
id lens yield reductions.
* Contributed to testing and implementation of Freon alternative (141-b) followi
ng change in environmental regulations and participated in formulating 141-b rec
overy method that resulted in cost savings.
K.B. ALLOYS, INC. (1988-1990)
PROCESS ANALYST
Oversaw aluminum alloying processes, troubleshooting issues and pinpointing root
cause of yield decreases. Tracked and analyzed raw material to identify negativ
e process patterns and changes, delivering observations and recommendations. Gen
erated reports for chemistry control charts and statistical analyses. Interfaced
with and supported R&D group in product development needs. Wrote/revised SOPs t
o reflect process improvements resulting from DOE testing and EVOP trials.
* Led quality improvement team in strengthening Boron-Aluminum alloy products vi
a DOE, enabling 5% yield improvement across all products and decreasing scrap.
* Created and rolled out EVOP program, including tracking database and statistic
al analysis tool, to drive improvement and optimization of core processes.
-- EDUCATION, TRAINING & AWARDS --
* Bachelor of Science in Chemical Engineering - University of Kentucky (UK)
* ACADEMIC HONORS:
UK/Dupont Chemical Engineering Scholarship
UK Academic Merit Scholarship
UK Commonwealth Scholarship
Dean James H. Graham Engineering Scholarship
UK Junior Chemical Engineering Merit Scholar
Tau Beta Pi Member (National Engineering Honorary)
Omega Chi Epsilon (Chemical Engineering Honorary)
* ESSILOR PROFESSIONAL DEVELOPMENT PROGRAMS
Designing Industrial Experiments
Project Management
Intellectual Property Workshop
Six Sigma for Managers
Vacuum Deposition Coating Training
Essilor Global Engineering Quality Management System Training
Global Leadership Training
Risk Analysis Training
Essilor Project Methodology Training
Essentials of Cleanroom Technology - Boston
Lean Sigma Leadership Training
Equipment Regulatory Content and Risk Analysis
Management Development Training
Statistical and Problem Solving Training
Lean Manufacturing training for Managers
Impactful Communication and Presentation skills
Drive for Change
* OTHER PROFESSIONAL DEVELOPMENT PROGRAMS
Statistical Process Control Training - Henderson Kentucky Community College Expe
rimental Design Course - Cincinnati, OH
Experimental Design and Evolutionary Operation Training - K. B. Alloys
Supervision for New Managers - American Management Association
Effective Communication for Managers - American Management Association
Microsoft computer courses (Project, PowerPoint, etc.)
Results-Oriented Communication for Managers -American Management Association
Cleanroom Design and Training Seminar - Monterrey, CA
Process Measurement and Control - AAB Instrumentation
* AWARDS WON AT ESSILOR
Engineering Excellence "Technology" Award
Global Engineering "Mass Production Expertise" Award
Global Engineering "Best Industrial Project" Award
* AWARDS NOMINATED FOR AT ESSILOR
CQI Silver Award
Engineering Excellence "Best Original Design/Solution Award
Global Engineering "Innovation" Award"
Global Engineering "Mass Production Expertise" Award
Global Engineering "Best Industrial Project" Award