BDB Solutions LLC is a team of Asset Management Professionals who has walked in your shoes. All of the BDB Solutions LLC team has actually turned wrenches, used meters, ran a crew, planned and scheduled work, eliminated failures, or led an operating or maintenance department at an industrial facility.
Blake A. Baca, CMRP, CRL
Owner/Asset Management Coach
Blake graduated from Texas Tech University in 1989 with a degree in Mechanical Engineering. Upon graduation from Texas Tech, Blake went to work as a mechanical engineer at Alcoa, Inc., Rockdale Operations in Rockdale, Texas. Alcoa Rockdale Operations was an aluminum smelter that made over 2,000,000 pounds of molten aluminum per day.
In 1995, after six years as a Staff Mechanical Engineer at Alcoa Rockdale Operations, Blake moved intoOperations as Area Supervisor responsible for the assembly of carbon anodes used in the aluminum smelting process. Blake had full accountability for maintenance and operations in this area including one operations foreman, one maintenance foreman, 17 hourly union production employees, and 8 hourly union craftspeople including mechanics and electricians.
Later that year at Alcoa Rockdale Operations, Blake was promoted to Maintenance, Engineering, and Environmental Area Supervisor responsible for all maintenance, engineering, and operation of environmental control systems in what is called the potrooms, the area of an aluminum smelter where molten aluminum is produced.
Blake held that position until 1999 when he was promoted to Maintenance and Engineering Superintendent at Alcoa, Inc. Tennessee Operations in Alcoa, Tennessee. At Tennessee Operations, Blake was responsible for all maintenance, reliability, and engineering for the entire smelting plant.
In 2001, Blake was promoted to Senior Staff Project Engineer at Alcoa, Inc. Primary Metals Business Unit Office in Knoxville, Tennessee. In that role, Blake served as Project Engineer for Primary Metals growth capital projects as well as reliability consultant to the Primary Metals Business Unit.
In 2004, Blake was once again promoted to Maintenance and Engineering Manager at Alcoa, Inc. Rockdale Operations where he had started his career with Alcoa. There he was responsible for all maintenance, reliability, and engineering for the entire plant. Blake held this position until the plant was shut down due to business conditions at the end of 2008.
In 2009 Blake began BDB Solutions, LLC. Since then, Blake, with some of his former Alcoa maintenance and reliability staff, who are employees of BDB Solutions, LLC has been providing consulting services with particular emphasis on Maintenance and Reliability. Those consulting services include Work Management Development, Maintenance Planning and Scheduling education and training, Reliability Centered Maintenance (RCM), Reliability Engineering, Maintenance Engineering, Equipment Maintenance Plan (EMP) Development, and Preventive/Predictive Maintenance (PM/PdM) Optimization.
Blake also served as Maintenance Manager for Barrick Gold Corporation (Goldstrike and Cortez Hills Mines) in Elko, Nevada from 2017-2019.
P.E. - Consultant
As a consultant with BDB Solutions, Adrian provides broad based services capitalizing on his skills and experience in engineering, quality management, and supply chain management. Adrian joined BDB Solutions following a 32 year career with Alcoa Inc. Adrian started his professional career with Alcoa following his college graduation as a mechanical engineer. He worked as an engineer for over 10 years, in a fully integrated facility that included an aluminum smelter, mine and power plant. At one time this facility was the largest aluminum smelter in North America with an operating capacity of 320,000 metric tons of annual aluminum production. As a Senior Engineer he provided solutions to support production and maintenance departments with projects that ranged in complexity and cost. One noteworthy project he led was the implementation of new casting technology with a capital expenditure close to one million dollars. After engineering, Adrian was promoted to quality supervisor and he spent the next 6 years developing and implementing quality systems internal and external to Alcoa. Following this period, Adrian was promoted to the commercial side of the business with various positons within the procurement department. He was a Senior Staff Buyer for the Smelter and then promoted to Procurement Manager for the operations. After three years he became Regional Procurement Manager responsible for three Alcoa locations in the US southeast region. Two years later he became US Procurement Operations Manager responsible for the Procurement Operations of 10 locations throughout the US. After four years he became a Global Sourcing Manager where he developed and implemented a strategy to manage an indirect material spend portfolio of $150M with $85M focused in North America. After retiring from Alcoa, Adrian became part time Adjunct Professor for the Austin Community College, teaching courses in lean manufacturing and industrial hydraulics. Adrian has traveled extensively to Western and Eastern Europe, Canada, Mexico and South America. Interestingly he snow skied down the Matterhorn in Switzerland and went deep sea fishing off the coast of Iceland. He has a son living in Denton, Texas. And today, he enjoys spending his time working on home projects, listening to his vast collection of recorded music, jogging and bike riding.
Adrian obtained a B.S. in Mechanical Engineering from the University of Texas at El Paso. He then went on to earn his MBA in Executive Management from University of Tennessee School of Business.
Professional Associations and Activities
- Texas Board of Professional Engineers – Registered Professional Engineer
- American Society for Quality – Certified Six Sigma Green Belt and Certified Quality Auditor
- Institute of Supply Management – Certified Purchasing Manager
- American Corporate Partners - Veteran Mentoring Program
Edward (Ed) L. Potter, CMRP
Senior Asset Management Coach
Ed is a mechanical engineer that graduated from Virginia Tech in 1978. Ed has over 35 years Alcoa experience in Smelting, Refining, Cast House, and Power Plant Operations. Ed’s roles include Plant Engineer, Production Engineer, Reliability Engineer, Maintenance Supervisor, Engineering and Maintenance Manager, Regional (US Primary Products) Maintenance Manager, and various other special assignments. Ed is a highly skilled craftsperson and Reliability Engineer with working knowledge with all Reliability Engineering tools.
Ed was instrumental in development of Alcoa’s Asset Integrity Assessment process. He authored and was chief auditor for 2 of the 6 Asset Integrity Protocols, and completed assessments and improvement plans at 11 of Alcoa’s 13 worldwide smelters. Ed was instrumental in development of Alcoa’s Maintenance Best practice sharing process and co-authored the Best Practice documents for; Maintenance Planning and Scheduling, Lubrication, Kitting and Staging, and several Asset specific Reliability Best Practices.
Ed developed Alcoa’s Pre-Production Reliability Activity (PPRA) process which focuses on designing Reliability into new capital installations. He implemented this process on the $500M expansions in Alcoa Mosjoen, Norway and the $600M installation of the SO2 scrubber at the Alcoa Warrick Indiana Power Plant.
Ed owns a small antique business and can often be seen restoring antique and vintage furniture and repairing antique mechanical clocks. Ed is currently finishing up a restoration of 1957 oval window Volkswagen Beetle. Ed is competitive handgun shooter and also avid weight lifter, having been a competitive power lifter in his younger years. Ed is a Certified Maintenance Professional (CMRP).
Jason D. Kukla, CMRP, CRL
Partner/Asset Management Coach
Jason has a Mechanical Engineering degree from the School of Mines in Rapid City, South Dakota and certifications related to maintenance and reliability leading practices. He has had an opportunity to gain experience in multiple industries including: power generation, mining, refining, corn wet milling and food manufacturing.
Jason grew up on a farm and cattle ranch in North Dakota and developed an early interest in equipment. In 1999, Jason took a job as a maintenance technician for Southwest Water Authority where he maintained raw and potable water systems including pipelines and water treatment facilities.
In late 2000, Jason started working at a pallet manufacturing company while obtaining his degree. Upon graduation from SDSMT, Jason went to work as a project engineer for Tate and Lyle, a corn processing facility in Loudon, TN. After learning the wet milling, refining, ethanol and specialty starch processes Jason migrated to the maintenance department and was later given operations and maintenance responsibilities for steam production and energy management programs as an Area Manager.
In 2006, Jason returned to the Black Hills area as a planning engineer for Black Hills Corporation, a regional power generation utility. In this role Jason planned, scheduled and executed plant turnarounds for multiple power generation facilities. In this role he helped develop a team of engineers which later assumed his strategic asset management (5-10 year CAP/MEP) and turnaround responsibilities.
In 2007 Jason was promoted to O&M Manager and kicked off an initiative to implement work management processes and replace the CMMS and financial/people management systems. Jason was also a key player in the construction, commissioning and startup of 2 coal fired power plants.
In 2008, Jason was promoted to Reliability and Performance Manager where he implemented condition based maintenance and a plant performance program. Plant performance monitoring and tuning was further enhanced with the installation of real time process monitoring software (OSI PI) and development of key performance indicators.
In 2011, Jason transitioned into the world of Food Manufacturing by joining Kellogg as the Senior Maintenance and Reliability Manager. In this role Jason had responsibility for maintenance, reliability and the MRO store room. This included 40+ salaried and hourly union workers.
In late 2013, Jason joined the Georgia Pacific team as a Reliability Leader at a gypsum facility where he was responsible for maintenance, reliability engineering and project engineering. Jason was later promoted to Assistant Plant Manager which added management responsibility for the underground mining operation.
Jason has been an Asset Management Coach with BDB Solutions LLC since 2015, and has been a BDB Solutions LLC Partner since 2016.
Jason enjoys spending time with family, home improvement projects, the outdoors, four wheelers, fishing, hunting and sports.
Josh Stoudt, CRL
Asset Management Coach
Josh Stoudt is a Certified Reliability Leader (CRL) that grew up in Blue Rapids Kansas where he enjoyed high school sports, hunting, fishing and dirt bike riding.
Josh graduated from Manhattan Area Technical College in 2005 with a degree in heating ventilation and air conditioning maintenance technologies.
Josh started his career with Central Mechanical Construction in 2005 as a service technician. Josh’s role as a service technician included commissioning new equipment, troubleshooting, corrective maintenance, preventive maintenance and predictive maintenance for all industry and facility types. During his stay at Central, Josh completed a 3yr mechanical apprentice program followed by earning his mechanical journeyman license. In 2010, Josh was promoted to superintendent of the service department.
In 2012, Josh joined the Georgia Pacific Gypsum facility in Blue Rapids Kansas as the Reliability Engineer. As the Reliability Engineer, Josh was responsible for the development and execution of asset strategies both on mining and surface equipment. Josh was also responsible for the maintenance department which included 8 mechanics, 2 utilities, 3 electricians and 1 loader operator. During his role as a Reliability Engineer, Josh completed a 10-week Reliability Excellence course hosted by the Georgia Pacific Operations Excellence Group.
In 2014, Georgia Pacific promoted Josh to the Reliability Leader position where he assumed responsibility for maintenance, maintenance planning & scheduling, engineering and projects which included 4 salaried direct reports.
In 2015, Josh joined BDB solutions as an Asset Management Coach.
Josh is married with two children and a dog. He enjoys hunting, fishing, coed softball and spending time with his family.
Ed Hemmersbach retired from Alcoa as the Vice-President of Alcoa Rolled Products, which serves the food and beverage can sheet, lithographic sheet, and industrial sheet markets in North America, and was one of Alcoa’s board members for the joint venture with Ma’aden in Saudi Arabia. Prior to the separation of Alcoa Inc., into Alcoa Corp. and Arconic, Ed was President, Alcoa Global Packaging (AGP), responsible for the Company’s business serving the food and beverage can, bottle, and lithographic sheet markets built on the capabilities of Alcoa’s rolled products plants in China, Brazil, Russia, Saudi Arabia, and the U.S.
Ed has held key engineering and management roles at Alcoa, including Vice President, Operations for AGP, Vice President of North American Operations for AGP and Location Manager, Warrick Operations. Earlier, he served as Operations Manager at Warrick, accountable for the manufacturing portions of the rigid packaging business there. He advanced into the Operations Manager role from his position as Manager of the Fabricated Products Division, where his 300+ member team was responsible for all aspects (EHS, quality, operations, maintenance and engineering) of the finishing department. Prior to that assignment, he was the Manager of Central Services at Warrick, leading the central maintenance, shops, and engineering functions, serving as site lead for the reliability excellence and TPM program.
Earlier in his career, he was employed by Commonwealth Aluminum (currently Aleris). During his time at Commonwealth, Ed held roles as engineer, area maintenance superintendent, maintenance planning superintendent, and maintenance manager and engineering manager, and procurement manager.
Ed has an extensive background in maintenance and reliability, operational excellence, and lean manufacturing. Ed received significant training internal and external training in reliability and maintenance excellence, lean manufacturing, organizational and business leadership, and has implemented transformational programs in all of these areas. Having personally implemented these initiatives and leading a global organization that heavily relied on these methodologies, Ed has a unique combination of experiences. This allows him to understand the strategic benefits and need for such transformational initiatives and fully grasp the realities of implementation and the practical application at the shop floor.
Ed graduated Magna Cum Laude with a BS degree in Mechanical Engineering from Rose-Hulman Institute of Technology.
He was a member of the Boards of Directors for both the Indiana Manufacturer’s Association and the Indiana Chamber of Commerce.
Walter L. Peschke
Planning and Scheduling Subject Matter Expert (SME)
Walter acquired a degree for Texas State Technical College with a degree in Mechanical Drafting and Design.
Upon graduation, Walter went to work for Texas Instruments in Houston as a Mechanical Designer. After several years in the Designer Role. Walter decided to change his career, and he started a lengthy career in the Power Generation Business.
Walter spent 37 years in various Maintenance roles in the Industrial Power Generation business; with companies like Texas Utilities, Alcoa, and most recently Luminant.
While in the Maintenance Support Group, his roles ranged from Supervisor, Planner, Scheduler, Planning Supervisor, Maintenance Manager, Outage Manager, and Reliability Supervisor.
Walter has a strong background in providing the knowledge of developing Asset Ownership. i.e. Reliability Excellence REX program with Alcoa, and also the L3 Work Management Process within Luminant.
Walter was also the site Functional Administrator for various CMMS systems over the years, ranging from eAM-Oracle, Empac, and Maximo.
The most recent CMMS project was Luminant’s acquisition of Dynegy in 2018. He was very instrumental in providing support for the testing, conversion, Integration, and migration of all the Dynegy data to the Luminant version of Maximo 7.5. Spent 6 months providing UAT testing, site training, and end user support to Management, Planners, Schedulers, Supervisors, Buyers, Contractors, and all site users. Very strong in CMMS functionality, Support Scheduling and PM Optimization.
With a strong Maintenance and Maintenance Reliability background, considered to be a leader in the Work Management process and development.
As a consultant with BDB Solutions, Walter provides the knowledge and leadership to enhance any Company in utilizing its resources, and develope a process in becoming a benchmark facility.