Australia Weatherall

Manufacturing and Operations Engineer with 3+ years of experience driving process improvement, operational excellence, equipment startup, and cross-functional project execution within manufacturing environments. Experienced in greenfield plant startup, Lean Six Sigma, root cause analysis, data-driven problem solving, project tracking, cost reduction, process optimization, and change management. Proven ability to coordinate engineering, operations, OEMs, contractors, finance, and corporate teams to implement solutions, resolve operational challenges, and sustain improvements.

Brings hands-on manufacturing expertise with a strong foundation in project management, stakeholder coordination, and continuous improvement.

Continuous Improvement Engineer - Jack Links Protein Snacks - Perry, GA (Greenfield Startup)

(2026-03 - 2026-10)

• Led continuous improvement initiatives using Lean Six Sigma methodologies to identify and eliminate non-value-added processes, improve OEE, reduce waste, and increase operational efficiency.
• Conducted weekly root cause analysis on top plant losses using 9-Square, FMEA, and fault tree analysis to identify process opportunities and develop sustainable corrective actions.
• Analyzed operational data and KPIs including yield, efficiency, and energy consumption to identify process deviations, prioritize opportunities, and support data-driven decision making.
• Managed project status updates, action tracking, stakeholder feedback, and escalation to support successful execution of improvement initiatives.
• Standardized project action tracking to improve visibility, accountability, and follow-through across improvement projects.
• Partnered with Finance to estimate cost savings associated with waste reduction and performance improvement initiatives.
• Managed OPEX cost-savings projects from implementation through process capability and sustainment, coordinating with corporate project engineers to transition projects into site ownership.
• Facilitated cross-functional meetings involving engineering, operations, finance, and other stakeholders to align teams and execute process changes.
• Applied DMAIC methodology to structure and close Operational Excellence projects while maintaining focus on measurable improvements.
• Used SCADA systems and visual management tools to monitor process performance and support operational decision making.
• Supported implementation of Total Productive Maintenance (TPM) structures to strengthen cross-functional ownership of daily operations.
• Developed quick-win improvement opportunities through statistical analysis, process monitoring, and Lean Six Sigma methodologies.

Process Engineer - Jack Links Protein Snacks - Perry, GA (Greenfield Startup)

(2025-02 - 2026-03)

• Supported the startup of a new raw-process operation from equipment installation and trial runs through SAT/FAT, performance guarantee activities, and equipment design.
• Served as startup leader for equipment installation projects, coordinating OEM service representatives, contractors, engineering teams, and site personnel.
• Commissioned new OEM equipment by completing pre-startup safety reviews, verifying P&IDs, and supporting equipment readiness for production.
• Coordinated corrective actions across site engineering, OEMs, subcontractors, and project teams while tracking follow-up activities through startup punch-list completion.
• Established processes and operating standards for a new greenfield manufacturing site in collaboration with contractors and cross-functional teams.
• Developed SOPs, one-point lessons, troubleshooting guides, reference materials, escalation plans, process flow diagrams, and operational maps to standardize plant processes.
• Created and implemented equipment baselines and process aids to support successful startup and operational readiness.
• Saved $40K+ through a parts savings initiative that increased operator ownership, improved equipment efficiency, and strengthened preventive maintenance practices.
• Started up plant databases and PLC configurations and partnered with startup contractors to validate OEM database tags for visual management.
• Supported wastewater startup activities, including jar studies, DAF installation, and pH optimization to meet permit criteria.
• Led and validated Management of Change (MOC) activities for process, safety, engineering, and operational modifications.
• Traveled as needed for data gathering, design reviews, training, and onsite operational support.

Process Engineer - Irving Tissue Mill - Macon, GA

(2023-06 - 2024-12)

• Applied Lean Six Sigma and root cause analysis methodologies to improve manufacturing processes, troubleshoot operational issues, and identify cost and efficiency opportunities.
• Managed an entire production asset and developed waste-reduction strategies to improve material utilization and operational efficiency.
• Delivered $95K in savings during one period through a corrugate and freight cost-reduction initiative in collaboration with an OEM.
• Planned and executed process trials designed to increase capacity, reduce downtime, and generate cost savings while following Management of Change procedures.
• Led process optimization initiatives involving automated guided vehicles, including mission-sequence optimization to improve machine OEE and reduce process deviations.
• Served as Process Technician/Operations Lead for broke and core operations, supporting preventive maintenance management, daily management systems, and standard work.
• Developed SOPs, trouble-cause corrections, one-point lessons, KPIs, and centerlines to standardize operations and improve process capability.
• Created PI Vision displays, process trends, and data tags to provide visual management and improve production-floor decision making.
• Worked cross-functionally with logistics, converting, operations, and engineering to maintain efficient plant process flow.
• Optimized converting procedures and daily broke consumption to improve efficiency and finished-product quality.
• Established and supported a site confined-space program and traveled for training, site assessments, and implementation activities.

Bachelor of Science - Paper Engineering - Western Michigan University (2023)