Project/Process Engineer - 03896sc

02-06-2002 Resides in South Carolina

Salary: US $

Relocate: Southeast

On the Market: Looking

Industry: Automotive

03896 Project/Process Engineer - Automotive

SUMMARY

Results oriented manufacturing professional with both hands-on and management experience combined with a diverse technical background.  Proven organizing and leadership abilities with superior communication skills at all levels of the organization from hourly workers through senior management.  Have always been given the jobs that couldn't be done and saw them through completion.

EXPERIENCE

"Confidential" SC. - An technical automotive business                       1996 to Present

Contract consultant, providing Quality mechanical inspection/assessment services to the automobile industry focusing on root cause analysis of mechanical damage. 

. Provided problem resolution to 100% of 500 + damage claims
. Resolved several dozen controversial claims at the 2nd and 3rd opinion level
. Provided expert testimony used in several litigated claims
. Recommended by Mercedes-Benz of North America to provide older vehicle owners with advise, appraisals and opinions

"Confidential" GA. - The world's largest manufacturer of golf cars and industrial vehicles              1999 to 2001

Maintenance Supervisor -- reporting to the Maintenance and Environmental Superintendent
Responsible for 18 Maintenance Mechanics providing production support to second and third shifts, covering over one million square feet of manufacturing facility.

. Participated on Kaizen and TQM Teams
. Authored job descriptions for four levels of Maintenance Mechanic
. Formally organized all second and third shift mechanics into functional teams to effectively address machine outage situations consistently realizing 60% + of work orders completed on second shift and 20% + completed on third shift
. Developed equipment prioritization matrix to schedule repairs and maintain overall plant uptime
. Organized and implemented 100% of the mechanics training programs covering boiler operations, specific machine tools, PLC's, HVAC repairs, basic training for new mechanics and in-house cross training between shifts to optimize technical repair expertise on all shifts.
. Developed and mentored individual mechanics motivational/improvement plans realizing 7 promotions respective pay raises and overall more effective maintenance mechanics.
. Directed the activities for all outside resources providing maintenance services during off shift hours
. Performed (4) comprehensive internal audits to help maintain ISO 9000 registration

q       North American Royalties, Inc./Wheland Foundry Division, Warrenton, GA. - Manufacturer of brake rotors and
drums for automotive and truck OEMs  1997 to 1999
Project Engineer, Maintenance -- reporting to the Maintenance and Engineering Manager

Drove all the division's capital and maintenance expense projects through completion while sharing supervisory responsibilities of 50+ maintenance personnel while directly supervising the activities of an AutoCadd drafter and maintaining all plant and equipment drawings.

. Leader of the company's JIT/Kaizen activities
. Financial justification and modification of two- (2) medium frequency virbatory mold shakeout machines
. Cost justification and implementation of experimental, automated in-feed and out-feed equipment for outside diameter grinder line
. Replaced FAILED cross collection conveyor in a 3-day holiday weekend to avoid plant wide production downtime
. Developed and implemented a device and stable production process for a mold inverting to eliminate the 85% scrap rate of the most profitable brake rotor manufactured by the company
. Developed and published over 2 million dollar capital plan for equipment over a two year period

Hubbell/The Ohio Brass Company, Aiken, SC. - Manufacturer of electrical insulators and arrestors               1991 to 1996

Senior Manufacturing Engineer -- reporting to the Engineering Manager
Provided production floor support and represented Production interests on new product implementation (Manufacturability) teams.

. Engineering participant on Insulator Department Kaizen Team
. Developed and implemented fixturing and a stable production process for a $300,000 assembly station that could not produce any prior product at all (a white elephant) and ramped up to $240,000 weekly shipments
. Written statements of work (SOW) and oversaw the installation and start-up for  $532,000 assembly equipment.
. Project engineer for over 2 million dollars of equipment from concept through release to production
. Represented Production and Maintenance interests on four New Product Introduction Teams
. Increased the production rate of an insulator assembly machine by 4 times which eliminated the need for a previously justified new piece of capital equipment
. Participation on the ISO 9000 Implementation Team resulting in first audit's successful registration
. Rewrote and prepared all documentation and SPC processes in the Insulator Assembly Manufacturing Department to conform to ISO 9000 requirements
. Wrote and prepared all documentation for the Maintenance Department to conform to ISO 9000 requirements

Sterling Inc., Milwaukee WI. - Manufacturer of water and oil temperature control units                              1989 to 1991

Manager, Industrial Engineering -- reporting directly to the Plant Manager
Responsible for all Manufacturing and Industrial Engineering aspects in the facility.  Leader of the company's Quality Circles activities.

. Cost justification for a new lathe, Manufacturing Engineering CAD/CAM system, and Product Engineering CAD system justified in less than two years and 28% under budget
. Identified and corrected inadequacies in accounting method of rolling up standard product cost for an accurate quoting process
. Delineated product rework conditions into three scenarios for more accurate reporting and better control

Cooper Power Systems, RTE Comp. Div., Pewaukee, WI. - Manufacturer of electrical insulators               1985 to 1989

Progressively promoted from Contract Engineer to Production Floor Support, to New Product Introductions to Manufacturing Engineering Supervisor supporting Manufacturability aspects in the Rubber Molding department and the day to day Production Floor Support of the sister plant in Taipei, Taiwan.

. Drove the 1st fully automated scrap removal system and a 2.4 million-dollar cost improvement program. Responsible for company's 1st JIT production area       . Conception and implementation of a prevention program for the PLC controlled molding presses and a 67% set-up time reduction in mold preheating


ADDITIONAL RELEVANT EXPERIENCE
Various contract and permanent position's activities as follows:

. Basic traditional Industrial Engineering responsibilities revolving around process development and time study, plant relocations, optimum layout design, space consolidation, and equipment justification/implementation at 6 companies.
. Plant layout activities for Johnson Controls, Inc. included Production floor layout for the wire fabrication area in Reynosa, Mexico, sole responsibility for the layout and equipment procurement of a distribution warehouse in McAllen, Texas, and the product transfers (incorporating manufacturability changes) and closing of a plant in Dallas, Texas. 
. Plant layout/consolidation activities at Gould/Gettys Motion Control eliminating triple redundancies in equipment, processes, and personnel.
. Drove a 77% manufacturing cost reduction for a right to edit switch and complete resolution of a massive switch failure problem at General Motors for Cherry switch.EDUCATION. Completed an AAS - Internal Combustion Engines Engineering Technology  & B.S.M.E. Technology Degree at The Milwaukee School of Engineering
. Time Management -- Franklin Quest Co.. Project Management -- Baldwin-Wallace College. SPC II Masters Series -- Technicomp. NC Programming -- Milwaukee Area Tech College. 2070 Mk II Maintenance - George Fischer DISA, Inc.. How To Supervise People -- Fred Pryor Seminars. Internal Auditing for ISO9000 - U of Georgia. QS 9000 Quality System Course -- Hattie M. Long, ITCA auditorPROFESSIONAL. Senior member and officer in the IIE.. Senior member in the SME.. Member Society of Automotive Engineers.      . Basic & Advanced Programmable Controllers - Allen Bradley Co.. Microcomputers in Industry -- Milwaukee Area Tech College. Quality Improvement Through Defect Prevention -- Philip Crosby & Associates. Metal Forming -- Milwaukee Area Tech College. Fundamentals of Oxygen Welding -- Milw. Area Tech College. Basic Boiler Operations - PBS Inc.. Effective Meeting Management -- Sandersville Regional Tech. Industrial Wastewater Treatment - Enviro Training Assoc.ORGANIZATIONS. Commissioner on the West Milwaukee Development Authority.. Director and newsletter editor on local Chrysler Club.. Officer and Director on the Mercedes-Benz Club of America.

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