Profile: Senior Manufacturing Engineer / Project Manager
~ Offering 20+ years of progressive experience in automotive lean manufacturing ~
Highly qualified and extensively trained manufacturing engineering professional with robust experience as a project lead who excels at directing cross-functional teams and coordinating multiple projects simultaneously. Solutions-oriented engineer with a solid command of automated assembly and material handling, robotics and vision systems, and automation troubleshooting. Skilled at analyzing, documenting, and providing well-calculated recommendations for individual part or process failures from a technical and operations perspective. Point person in managing large capital budgets and capital acquisition expenditures; expert in installing new systems and capital equipment on-time and within budget.
* Well-versed in QS/ISO-9001, TS-16949, and AS-9100.
* Proven abilities in Eight Disciplines (8D) root cause and corrective action planning and execution for the supplier and the customer.
* Consistent successful project execution, with deliverables on time and at or below budget.
Strengths include:
* Risk Controls
* Process Improvement
* Poke-Yoke/Mistake Proofing
* Primary Problem Diagnosis
* Automation Troubleshooting
* Quality Assurance
* Work Flow Planning
* Product Lifecycle
* New Product Introduction
* Process Improvements
* Capital Equipment Specifications
SELECTED CAREER HIGHLIGHTS INCLUDE:
* Created and implemented installation aids cutting installation time and resources in half, reducing installation cost from $16K to $4K.
* Facilitated the in-house manufacturing of a z-spring for the Chrysler 45RFE/low/reverse roller clutch rendering a savings in excess of $300K annually with an ROI of less than 3 years.
* Team leader for the utilization of $2.25M in capital for the clutch housing used in the cutting edge BW-TTOD system for the 2001 Acura MDX AWD System generating $60M in annual revenue and winning the 2001 Motor Trend SUV of the Year,
* Served reservist duty, Illinois National Guard, honorably discharged.
CAREER EXPERIENCE
Agilent Technologies Inc. ª Santa Clara, CA ª June 2010 - Present
New Product Introduction (NPI) Manufacturing Engineer - Advanced
Responsible for pilot builds and release to production of electro-mechanical nuclear magnetic resonance (NMR) automation products. As a member of the cross functional NPI team, responsible for creating and implementing the manufacturing plan with respect to manufacturing feasibility, Design for manufacturability and reliability(DFx), manufacturing process design, supplier selection, and packaging design. Provide NPI and sustaining engineering support with domestic and South East Asian Contract Manufacturers (CMs), including training, process transfer, and set-up.
* Successful NPI launch of significantly revised automated NMR sample delivery system, (7620AS).
- Delivered on-time and within budget
- Recommended significant design changes in the LP Build phase that greatly improved ease of assembly, installation, and reliability.
- Provided input that improved the packaging which reduced damage and transit cost.
- Improved hardware shipping methods to reduce the installation time at the customer site.
* Co-Chaired weekly Continuous Improvement (CI) meetings and contributed to reducing defective-on-arrival (DEFOA) rate for automation products from approximately 8 instances per month to less than 1 instance per month.
* Determined root cause and implemented successful corrective actions in conjunction with supplier of robots used in a NMR sample changer suffering from multiple failures with three discrete failure modes, (7620AS).
* Successfully introduced product changes to lower cost, reduce defects and increase market share.
- New material for sample carrier used by 80% of customers that reduced cost by 80%.
- New variants of current sample delivery tubes that allowed sales onto competitors systems.
- New sample delivery tube variant for next generation NMR system.
* Chaired meetings to create a formal First Article quality procedure as a result of an ISO audit finding.
Benchmark Electronics, Precision Technologies Inc. ª Concord, CA ª May 2008 - June 2010
Senior Manufacturing Engineer
Delivered NPI and sustaining engineering of medical, aerospace and semi-conductor capital equipment product lines. Leader of cost reduction project, focused on reducing waste, increasing margin and improving manufacturing efficiency. Responsible for disposition of Material Review Board (MRB) inventory, including Work in Process and customer returns, with focus on continuous reduction of MRB inventory through effective corrective action.
* Designed and implemented processes, BOM's, routings and documentation to effectively manufacture new parts on time and within budget.
* Effectively solved supplier quality issues through active engagement with supplier(s), eliminating downtime and improving manufacturing throughput.
* Reduced monthly MRB inventory from $150K to less than $50K through effective corrective actions.
BorgWarner Transmission Systems, Inc. ª Bellwood, IL ª February 1999 - April 2008
Senior Manufacturing Engineer, High Volume Automotive Mechanical and Wet Clutch
Responsible for NPI, production and sustaining engineering activities on 13 automated OEM production lines with sales of more than $75MM. Allocated multiple internal and external resources in support of new product introduction. Involved in all manufacturing launch phases of the product lifecycle: Manufacturing feasibility, DFM, prototype, alpha, beta and mule samples to high volume mass production, including service, aftermarket, and product obsolescence. Traveled extensively in the U.S., Canada, Mexico, and Europe in support of capital projects related to new product launches. Led the introduction and development of CNC machining as a new core competency at BW-Bellwood, a traditional metal stamping plant. Supervised multiple continuous improvement projects minimizing defects and costs by using lean techniques such as Kaizen events, 5S and Six Sigma techniques. Recommended and applied process flow and quality improvements, created process drawings, work instructions, process FMEA's, control plans, BOM's, and routings.
* Specified, purchased and installed custom automated capital equipment for the following transmission programs:
- $1.13M in capital for the Chrysler 62TE transmission generating $2.2M in revenue annually.
- $1.5M in capital for the GM 6L50/80/90 & Chrysler 68RFE transmissions generating $15M in revenue annually.
- $1.3M in capital for the Aisin Warner B700 & B800 transmissions generating $10M in revenue annually.
- $2.25M in c...
Login or Register to view the full resume.
