CAREER SUMMARY
Experienced in Operations Management and Project / Manufacturing Engineering Management. Expertise includes; the management of product development and the manufacturing process resulting in the production of cost and quality compliant products, developing/executing project plans, diagnosing /solving technical/business challenges and conceiving ideas for cost effective solutions. Excellent mechanical/technical aptitude and knowledge of structured problem solving tools (Shanin)
WORK HISTORY
2014-Present Senior Manufacturing Engineer, Consultant to GM, Lockport New York. Hired as a consultant to solve a
$7500 per/day quality issue using my structured problem solving background
2011-2014 Lead Project Engineer/ Senior Manufacturing Engineer HVAC, Delphi Thermal Systems
Lockport, New York. Duties included:
• Preparation of plant manufacturing sites to begin the manufacturing of new products
• Acquired ≈ $1.0 M of capital equipment to support the lean production of a 2014 and a 2017 HVAC system. This included:
o Directed Manufacturing System Design workshops to facilitate how new products will be manufactured. Output of these workshops included plant layout, operation sequence, labor standards, machine and operator utilization estimates, and new equipment, tools and fixtures requirements.
o Estimated the cost of new equipment, tools and fixtures to manufacture new products
o Reviewed new manufacturing system design(s) with the matrix organization (the organization included Chief Engineer, Program Manager, Product Design Engineers, PC&L, Advanced Engineering and Finance)
o Preparation of Appropriation Requests to acquire new equipment, tools and fixtures
o Preparation of equipment acquisition project schedule
o Preparation of request for quotation for acquiring new equipment, tools, dies and fixtures
o Generation of new equipment, tools and fixture specifications
o Participated in supplier selection for equipment, tools and fixtures (source selection per corporate standards)
o Interfaced with the Purchasing organization to manage new equipment , tools and fixtures change orders
o Over saw suppliers during the design, manufacturing and acceptance of acquisition of new equipment, tools and fixtures.
o Managed the new equipment budget
o Directed Design for Manufacturability (DFM) studies of new product design data
o Utilizing generally accepted statistical methodology directed, conducted or participated in equipment capability studies. Output provided in Mini-Tab
• Generated Advanced Quality Process Documents (Process Flow Diagrams, Control Plans and Process Failure Mode Analysis)
• Trained Operators and Maintenance personal with respect to “man machine” interface
• Provided leadership during two new product launches
• Provided input to the internal change management process as required
2010-2011 Special Assignment General Motors, Spent ≈ one year cross training UAW skilled tradesmen.
Cross training was conducted in a sensitive Union/Management environment. End result of this cross training allowed a labor contract change which saved the company more than $250,000 per year in maintenance labor costs.
2008-2010 Senior Manufacturing Engineer Power Train Cooling, Delphi Thermal Systems
Lockport, New York
Direct leadership responsibilities of four Manufacturing engineers, one Industrial engineer and one Controls engineer. Responsible for providing lean continuous engineering improvement direction for two large manufacturing departments. Responsible for successfully altering the engineering, quality and manufacturing process to accommodate current business demands.
• Supervised the 6 engineers that reported to my team with respect to developing process improvement projects that supports the overall organization’s requirement
• Provided input to each of the 6 engineers annual performance review that reported to my team
• Prepared an managed two large heat exchanger manufacturing department’s Manufacturing, Controls, Industrial Engineering and Maintenance budgets
• Participated in a cross functional team that developed hourly direct and indirect manpower requirements using process flow diagrams, equipment rearrangements, material presentation and plant layouts that allowed the manufacturing organization to flex as customer requirements changed
• Managed compliance to TS16949 (Automotives ISO 9001 equivalent) and ISO 14001 requirements
• Focal point for TS16949 and ISO 14001 audits. Included Process Flow Diagrams, Control Plan and PFMEA walks with internal and external auditors. Addressed all non-conformances found.
• Oversaw and utilized structure problems solving techniques in my area of responsibility to improve Operational Equipment Effectiveness. This included three key components:
o Equipment operational availability
o First time through quality
o Process output (operator effectiveness)
• Developed long and short term plant manufacturing process direction. Made two significant process improvements:
o Facilitated a change from thermally degreasing forming oil to water base based forming oil. This provided three major benefits:
Allowed a change to a subsequent wash process that initially allowed the wash to be discharge into the sanitary system without treatment
Improved air quality within the plant
Finally the elimination of the wash process. This avoided purchasing new wash equipment. This cost avoidance was in excess of $500K.
o Refined a forming and brazing process that resulted in a 22% first time through quality improvement
Lead a cross functional team that resulted in a heat exchanger product change
Engineered new braze profile that influence clad fluidity
• Participated in Site safety review and improvement activities
o Oversaw the annual review of all equipment lock out placards and lock out procedures with in my area of responsibility
o Provided corrective action for all occurrences of near misses, minor injuries and lost work day cases with in my area of r...
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