Operations & Process Engineer
José García Herruzo
I find what costs you money.
Then I fix it.
15 years turning industrial plants into measurably better operations — through process engineering, production ML, and large-scale operational leadership.
€0M+
Annual OPEX managed
0+
Team members led
0%
Fewer production incidents
0%
Less overtime spending
0 GWh
Energy recovery identified
0 yr
Industry experience
Where I've done it
- Managing +€22M OPEX with under 2% forecast deviation — two consecutive years
- Led a 100+ person team; technician performance lifted from 20% to 80%
- Cut production-impacting events by 50% through proactive root-cause analysis and cross-functional coordination
- Reduced customer quality incidents by 15% via structured bi-monthly feedback reviews
- 60% reduction in overtime spending through redesigned shift planning strategy
- Delivered >95% on-time complex shutdowns integrating Engineering, Production and Logistics
- Implemented coaching and feedback system raising employee engagement scores +25%
- Built 5+ ML models running in production: catalyst behaviour, SO₂ emissions, gas management, capacity monitoring, catalyst activity
- Catalyst pressure-drop prediction model: saved 20+ production days
- Acid quality study: identified wrong technology selection, saving ~€2M capex
- Energy Management: 30% refrigeration water reduction, 10% blower consumption cut, 200 GWh/year recovery potential mapped
- Gypsum plant capacity: 58% → 80%+ via Six Sigma root-cause analysis
- Emission Reduction Plan: −15% per plant across 3 sulphuric acid plants
- Shift Manager for 3 general shutdowns (catalyst replacement, 30 workers each)
- €6M Steam Gas Reduction project — Project Manager
- HAZOP staff: SA Plant 3 (2019), SA Plant 1 Heat Recovery (2020)
- Led basic engineering and simulation across multiple biofuel technology lines: MSW-to-ethanol, enzymatic ethanol, biobutanol (Fischer-Tropsch)
- Built BECS — internal tool that standardised and automated basic engineering documentation packages, adopted across 3 Abengoa business units
- Responsible for energy integration across all project areas
- HAZOP staff: Fulcrum Sierra Biofuels Plant
- Cobre Las Cruces (2011–12): Built KPI and OEE tracking tools in OSIsoft PI / VBA from scratch
- CEPSA (2011): Modelled and optimised a Depentanizer Tower in Aspen Hysys
- e-ON (2009): Laboratory technician — water-steam cycle control, emissions network monitoring
How I do it
Engineering
Aspen Plus ✓
Aspen Hysys ✓
Six Sigma Green Belt
HAZOP
Energy Management
Process Simulation
DWSIM · ChemCad
PMI / Agile (2024)
Data & Code
Python
Machine Learning (sklearn)
OSIsoft PI
Snowflake
SQL · SQLite · MariaDB
InfluxDB
MongoDB
Power BI
Grafana
JavaScript · NodeRed
Leadership
Operations management
OPEX budgeting (+€22M)
100+ person teams
Shutdown management
Cross-functional coordination
Coaching & feedback
Built & published
Chemical Engineering
ETSI Universidad de Sevilla · 2005–2012 · 360 ECTS
Best Final Thesis Award — oil refining & petrochemical area (CEPSA)
Programme →Master in Production Management & Industrial Process Improvement
OBS / Universidad de Barcelona · 2016–2017 · 60 ECTS
Programme →Certifications & Courses
Aspen Plus Certified User
Aspentech · 2021–2024 · Credential 00004761
Aspen Hysys Certified User
Aspentech · 2020–2023 · Credential 00004522
A4E Analytics for Everyone
DataCamp / Freeport McMoran · 2021–2022
Python 99th · Data Visualisation 100th · Statistics 95th percentile
Six Sigma Green Belt
Caletec · 80h
Horizontal Leadership Cycle
Otto Walter Internacional · 2022 · 4-month programme
Thermodynamics for Process Engineers
Inspyro · 33h
Economics & Financial Analysis
Escuela de Empresa · 2012–2013 · 200h