Brian O’Donel, P.E. Facilities Engineer & Workplace Safety Expert

Experienced in facilities/plant engineering & maintenance, facilities systems, building and grounds year-round and winter maintenance, industrial production machinery and processes, product development, material science and failure analysis, building construction and maintenance, contractor management, security systems and management, environmental, health and workplace safety.

Experienced in the recognition, evaluation and control of hazards in facilities/plant engineering & maintenance; facilities systems; building and grounds maintenance; industrial production machinery and processes; machine design and safeguarding design, installation, and maintenance; product design, development, and testing; material science and failure analysis; building construction and maintenance; environmental, health and workplace safety.

Facilities and Plant Engineering: Systems design, installation, integration and maintenance; industrial systems; electrical, mechanical, plumbing, pumps, motors, compressed air, heating and cooling, humidification; roofing; floor care and safety; doors; overhead doors; lighting; security systems; energy management and systems; warehousing; material handling; lift trucks operation, maintenance, safety, and training; dock systems; trucking; hoists & cranes, conveyors, conveyor design, fabrication, and maintenance; maintenance management; contractor management; machine shop management; waste streams and recycling equipment; code and regulatory requirements; ducting; cyclones and balers; parking lot maintenance.

Machine Guarding, Machine Operation & Safety: Machine safety; machine guarding design, fabrication, installation, and maintenance; equipment relocation, rigging, and layouts; assessments and abatements; OSHA compliance; electrical and mechanical; guard devices.

Safety Compliance, Procedures & Requirements: Environmental Health & Safety; workplace & industrial safety; union & non-union environments; OSHA compliance; fall protection; injury investigations; safety management and training; policies and procedures; injury investigations and abatements; ergonomics and soft tissue injuries; slip/trip/falls; emergency response teams and management; hazard communications; Lock Out/Tag Out.

Environmental Management: EPA, OSHA and DOT compliance; waste stream management, waste handling equipment and systems, permitting and manifesting, hazard communication, MSDS management, chemical exposure and contamination.

Tree Management: Property management and safety; contractor management; tree felling and cutting techniques; equipment, wood chippers, saw mills, chainsaw operation and safety.

Tools and Equipment: Fork and clamp trucks; printing equipment; hydraulic and pneumatic equipment; injection molding; machine shop machinery and fabrication processes; maintenance equipment and hand tools; loaders; snowplows and snow removal equipment; excavation equipment; agricultural equipment; gas powered chainsaws; wood working equipment; hunting equipment; crossbow guarding and safety.

Specialty Industries: Injection molding and composites; printing; hospitality (hotel, restaurant, resort); heavy equipment brakes & clutches; hydroelectric power generation, power station equipment; agriculture and livestock production; fencing; agricultural equipment and process safety; tractor and attachment operation and safety; loaders; excavation equipment; snowmobiles; ATVs; animal training and control; construction; snow and ice removal/winter maintenance; property surveying.

Professional Experience

Provide technical investigations, analysis, reports, and testimony toward the resolution of industrial, commercial, product, and personal injury claims and litigation involving facilities, building and grounds, plant engineering and maintenance, warehousing, machine guarding and operation, machine design; industrial and premises safety, injury investigations and claims; product design, manufacture, and testing; production systems, production and manufacturing equipment and systems; OSHA and environmental compliance; property management; tree management; agricultural and equipment safety; product liability and safety; machine safety; conveyors; overhead doors; lift trucks, fork trucks; warehouse storage and racking; chainsaws; crossbows.

Provided technical consulting and management of waste stream and compliance projects and ensured regulatory compliance associated with a large manufacturer of vehicles/motorcycles including distribution center operations.

• Directed Corporate Environmental Health and Safety 50+ facilities/~10K employees, plant and corporate management, distribution center management, department management, legal department, generate/train policies procedures.
• Managed safety and compliance, OSHA compliance, machine guarding design and compliance, workstation design and safety, emergency response; multi-plant
• Managed environmental compliance; EPA compliance, single & multiple plant.
• Managed facilities/plant engineering and maintenance, single and multi-plant
• Continuous improvement, Lean/Six Sigma, direction, management, multi-plant
• Machine design, fabrication, integration, installation, and maintenance
• Design, installation, implementation and maintenance of facility & manufacturing systems; production equipment, compressed air, humidification, heating and cooling HVAC design/maintenance, boilers, roofing, floors, structures, overhead doors, plumbing, mechanical & electrical, ducting, waste streams, waste handling and recycling systems, balers and shredders; single and multiple plant.
• Designed, installed, maintained security equipment, policies and procedures for the products and management of secure and negotiable documents for banking, healthcare and government etc., including security investigations.
• Responsible for machine guarding and OSHA compliance; including assessments, design, installation, implementation, policies and procedures.
• Generated and conducted training modules and training procedures.
• Managed, directed, and improved multiple site manufacturing plant ergonomic and soft tissue injury performance.
• Safety accomplishments include corporate wide direction, program definition and implementation that improves safety index from 5.56 to 1.24 over 5 year period, reducing claim costs by more than $2 million/year. Reduced soft tissue injuries and slip/trip/falls and injury severity company-wide.
• Responsible for plant and multiple site energy management.
• Managed all phases of building management and improvements, construction projects, construction management and compliance, maintenance systems, contractor management, designed manufacturing equipment and processes, conveyors, material conveyance, material storage and handling.
• Coordinated equipment moves and layouts, plant closures and relocations, rigging, commissioning/start-ups, and logistics, personnel, human resources.
• Led companywide environmental compliance and green initiatives, FSC, SFI.
• Managed OSHA and EPA inspections and abatements, Hazard Communication, MSDS management.
• Managed and conducted all facets of accident, failure, and loss investigations.
• Trained and experienced in Six Sigma, Statistical analysis, failure analysis, FMEA application, mistake proofing, lean manufacturing, and product safety.

• Research and product design, development, and testing for composites, friction materials, brakes, clutches for automotive, aerospace, and heavy equipment.
• Facilities engineering and maintenance, machine shop, project management
• Strength of materials analysis and testing.
• Managed injection molding, polymer and composite development.
• Lab management and testing, dynamometer development and testing.
• Significant work with Caterpillar, General Electric, John Deere, Ford, GM, Whirlpool, Morton Thiokol, Polaris.
• Industrial safety and compliance.

• Hydroelectric generating station mechanical and electrical maintenance.
• Heavy industrial equipment, power production systems, control systems
• Generating equipment rebuilds, concrete structures, water and compressed air.
• Overhead cranes, rigging, and safety.
• Engineering and construction projects.
• Machining, welding, fabrication, metallurgy
• Property surveying.

• Facility interior maintenance and equipment and facilities, retail: restaurant, bakery, and aquatic facilities, customer premises safety.
• Exterior winter maintenance: plowing and snow operations, grounds care, parking lot care, walking surface care and safety.
• Property management, maintenance and premises safety, plowing and snow removal operations, grounds maintenance, lawn mowing, parking lot care.

• Farming and farm equipment, property management and safety, land management, lifelong experience
• Farm equipment operation, tractors, loaders, maintenance and safety, excavation and excavation equipment operation and safety
• Timber management, forest stewardship, timber and firewood cutting, sawmill operation experience, land clearing
• Animal training and control, cattle, sheep, horses, rodeo horses
• Gates, fencing, containment, facility maintenance and safety

Professional Credentials

• Professional Engineer: Alabama, Arizona, California, Colorado, Connecticut, District of Columbia, Florida, Georgia, Illinois, Indiana, Kentucky, Louisiana, Maryland, Massachusetts, Michigan, Minnesota, Mississippi, Montana, New Jersey, New York, North Carolina, Ohio, Oklahoma, Pennsylvania, South Carolina, Texas, Vermont, Virginia, Washington, West Virginia, Wisconsin
• Six Sigma Black Belt, Master Black Belt, Certified
• Lean Manufacturing, Certified
• OSHA 30-Hour, OSHA Machine Guarding, OSHA Trainer, Certified
• Hazardous Waste, RCRA, DOT, HAZWOPER, Certified
• Fire Response training and management
• Green Building training, SFI/FSC Certifications

Education

B.S., Mechanical Engineering, Pennsylvania State University

Continuing Education

(Recent 2021-2024):

• Ethics for Licensed Professionals, 2024
• Engineering Ethics: Case Study of the Goodrich Aircraft Brake Scandal, 2024
• Selection and Sizing of Air Release Valves, 2024
• Introduction to Metal Fatigue - Causes and Cures, 2024
• Learning from Failure: Engineering Disasters, 2023
• Ethical Principles and Professional Conduct, 2023
• Engineering Ethics: The Great Boston Molasses Flood, 2022
• Determining Negligence in Engineering Failures, 2022
• Finding the Root Cause, 2022
• The Challenger Disaster and the Story of "The Five Lepers", 2022
• Introduction to Design for Manufacturing, 2022
• Heating, Ventilation, and Air Conditioning, 2021
• Professional Ethics 101, 2021
• Basics of Machine Learning, 2021
• Professional Ethics for Engineers, 2021
• Pumps, 2021
• Selection and Sizing of Pressure Relief Valves, 2021
• Valves, 2021
• Introduction to Metallurgical Failure Analysis, 2021
• Amazing Science of Steel, 2021

Awards

• Pennsylvania Governor’s Award for Safety Excellence
• Pennsylvania Governor’s Award for Environmental Excellence
• Associated Builders and Contractors Project of the Year

General

• Agriculture: 30+ years, crop and livestock production, tractor operation, equipment maintenance and operation, hay, straw and grain
• Wood working and construction, construction equipment
• Hunting equipment, tree stands, archery equipment and firearms, significant crossbow experience, crossbow guarding
• Land surveying, 30+ years work for licensed professional surveyor
• Resort services, snow removal & grounds maintenance, lawn care, mowing
• Snow plowing and removal, walkway and entrance care for hotel/restaurant complex as well as farm and residential snow plowing experience; equipment operated: truck plow, tractor plow, crop row tractors and equipment, tractor front end loaders, various farm machinery, snow blower, salt spreader, aerial lifts, dozers and loaders, backhoes, track hoes, snowmobiles, ATV’s.

v. 09/21/26