SUMMARY:

• Proactive, highly communicative, Manufacturing, Project, Lean, Electrical Engineering Maintenance in automotive injection, molding, chemicals, and rubber TPS (Toyoda Production Systems, Lean, 6 Sigma, and PMP).
• Demonstrated ability to commission plants, products, processes, and machines, lead, manage, and guide large and small teams of diverse disciplines, design, implement, and manage multiple projects, drive down costs through keen purchasing skills expanding the bottom line.
• Innovated, specified, modified and applied multiple manufacturing products, plants and systems, safely near doubling plant capacities, reduced labor requirements and overall improved plant efficiencies by near eliminating unplanned plant downtime.
• Communication always kept at a high level to the customers, engineering, operations and the board.
• Grew a single shift money losing plant to a 7/24 money making operation increasing the engineering and maintenance staffs from 3 maintenance men to 2 engineers, 1 technician, 1 maintenance manager, and 15. Managed up to 26 direct reports at a time.
• Identified, acquired funding ($850k) for and applied 15k gallon disperser mixing system and upgraded process equipment to capture new business increasing gross profits by $3.5 million in 3 months.
• Trained maintenance eliminating unplanned downtime.
• Program multiple SCADA, PLC, HMI, motion controllers, and drive languages communicating across various networks such as TCP/IP Ethernet, Modbus & plus, Profibus 485, 422, 232 and various Allen Bradley (Rockwell) networks. The keys are concise accurate animation and information, closed loop controls with accurate and repeatable feedback and condensed accurate information or exception reports placed at the touch of a key to those responsible for the decisions to manage their respective operational areas. Animating an area, minimizing intervention with continuous and flawless production defines success.
• Launched 15,000 - gallon disperser mixer for $850k in 3 months allowing plant to change from a single shift money losing operation to a 24/7 money making operation turning returns of excess of $3.5 million. Programmed 15k mixer in Rockwell Factory Talk & Studio, for the HMIs (PC based) and Contrologix distributed controller system and replaced all the VFDs (27) with AB ethernet drives. Also integrated in all the associated processes and machines.
• Upgraded 2 dual 270 4 story Bandbury mixing systems from PLC5s to Contrologix and Wonderware.
• Designed, launched, upgraded and established multiple small, medium to larger sub-systems, machines and processes with Allen Bradley (Rockwell) processors and PanelView HMIs using CompactLogix, 1500, SLC, MicroLogix, PicoLogix, PLC2, 5 and various others. Also programmed in multiple other PLCs, VFD drives, Servos, Steppers, and linear actuators.
• Established efficient operation of 47 injection presses increasing productivity by 21% through machine monitoring, team Kaizen, and operational efficiencies.
• Team Kaizen defined and applied R&D injection press to evaluate new and existing products increasing business sales by 13%.
• Established multiple R&D measurement and production equipment.
• Routinely reviewed automotive, mechanical, chemical and consumer products for development and established processes to support their launches including all real estate and utilities.
• Repurposed, modified and maintained multiple manufacturing, distribution and warehousing facilities with their respective infrastructures, utilities and associated government regulations.
• Weekly defined and estimated controls, machines, processes, repairs, and devices.
• Managed divisional/plant projects returning the investment within a year. Includes defining, designing, capital approval and managing.
• Staff level manager guiding process and product improvements and leading culture changes.
• Designed and modified several production mechanisms, devices, machines, processes and control systems targeted at waste reduction, greater throughput, labor reduction, quality improvements, energy reduction, and setup times. Launched several servo designs both electrical and hydraulic.
• Upgraded 80% of the plant's VFD drives added a 12-and-a-half-ton HVAC for conference and lab, added a 1.5-million-ton boiler to the experimental lab, added 4 heat pumps to the corporate offices, a stand furnace to the QC lab and repaired 8 heat pumps +/- 1.5 degrees.
• Defined, established, and modified plant P&IDs, one lines, IDEM/EPA Title V and engineering standards. Halved ambient LEL levels by covering all generators, applying automatic vacuum systems and valving required, increasing existing system by 32%.
• Lead stablishing and maintaining QS, ISO, Title V and other government regulations.
• Lead a multiple discipline group developing enterprise parts stores system to keep track of parts, reorders, machines and individuals. This identified opportunities for improvements in training management, equipment improvements, and parts costs. ($1.5M annually)
• Upgraded 7-coordinated axis rubber calendaring system saving $3M annually, formed 3 bias cutters into one at 170% speed repurposing 7 operators over 3 shifts. ($663k ROI).
• Designed leak free dynamic inline mixing system saving $1M first year and $2M each successive year eliminating scrap hazardous paste. System replaced continuously leaking rope seal systems with air seal leak less one converting waste into sellable product.
• Ace troubleshooter resolving difficult challenges on all equipment resulting in high quality product delivered to the customer 100% on time.
• Programmed key operating indicator tracking system to control the operation's quality.
• Defined, designed, developed, refined, and maintained multiple and automatic automotive coating systems including chain, rotating, belt loaded, dipped, and multiple dipped processes.
• Designed, applied, and maintained robot systems to the manufacturing and paint processes. Types of robots Fanuc, ABB, Prab and Cognex.

PROFESSIONAL EXPERIENCE:

Confidential , Goshen, IN

Sr. Automation Manufacturing Engineer (Lean Team)

• Defined and applied an automated saw system to cut aluminum treads and changing the fastener arrangement for $77k returning over $1.5M annually based on bump up from 100 a week to 3700 a week completed in 5 weeks using TPS.
• Launched Lincoln Power Wave Welder Data Collection system to analyze and justify a $420k dual Fanuc robot system targeting $574k ROI on an automotive saddle application. (6 weeks)
• Partnered with Lincoln for a dual robot Power Wave system to weld torsion axles for $370k to save $375k by redeploying manual weld operators to other areas.
• Defined a dual robot laser weld system for $500k to replace manual weld operators returning $480k annually however insuring 100% axle reliability and capability to add other welds.
• Designed and approved a quad rail spot welding system for $380k slated to return $400k a year. (6 Weeks)
• Defined a 2-robot weld system to weld up high volumes steel stairs for $380k slated to return $420k annually. (6 Weeks)
• Defined and got approved new versatile axle line to meet new customer volume demands for $180k flexible to run all axles f24-108”. (7 Weeks)
• Defined and approved actuated wall rail system for $180k slated to save $240k annually and meet increase in customer demand. (7 Weeks)
• Designed and implemented a pin box pin driver for $1.5k meet increased customer demand.
• On Green Field team to launch 474k square feet with equipment to break ground in June.
• Lean Team 45 staff member weighting in and performing single point flow designs. Performed several times, Takt, and load leveling studies.
• Defined capital budgets.
• On many other teams, performed many feasibility studies and made recommendation and implemented several efficiencies.
• Designed a powder coat tracking system to capture run times and speeds resulting increasing throughput by 20%.
• Established AB, ABB, and other support programming licenses for $17k versus $27k.

Confidential, South Bend, IN

Sr. Manufacturing Engineer/Engineering Manager

• Engineering and Staff level manager either leading or contributing to critical facility improvements like saving $200k annually by increasing nitrogen systems capacities without adding additional systems, improving tank farm level sensing, increasing tanks in real estate poor facility to eliminate supply chain issues, increasing critical information to operational teams to improve the processes efficiencies to mention a few.
• Responsible for hiring, terminating, training, mentoring and administering performance evaluations along with routine participation in or leading focus teams.
• Defined multiple cost effective robotic and automatic cells with return on investment from 6 months to 18. One was a 5-week personal challenge from the general manager to capture 6 million dollars in additional revenue yielding $2M in profits in the first year.
• Evaluated, acquired, retrofitted and repurposed a remote 357k square foot facility for product warehousing and distribution.
• Modifications included foam fire protection, HVAC upgrades, addition of 12' docks with levelers, file server room, 12-foot doorways, interior and exterior lighting, new 6-ton fork trucks, foam sprinkler upgrades, interior and exterior painting, safety upgrades, files room, modern burglar alarm & access system, plumbing changes, video surveillance, roof replacement, driveway repair to mention a few.
• Stabilized a critical 450-ton chiller running the 254,000-square foot facility.
• Designed and applied critical, poke yoke, chemical dispensing system with a 0.02-pound tolerance. Additionally, designed a Profibus chemical dispensing system.
• Designed acquired and applied a $27k critical thermal exchanger eliminating a process bottleneck increasing through put by 47%. This allowed the plant to meet the increased customer demand.
• Lead/applied several facility improvement incentives to increase safety, health and employee wellbeing. Some included roof replacement, lighting upgrades, equipment grounding and bonding in a highly explosive solvent environment. Replaced and rebuilt leaking and faulty valves, pumps, pipes, sensors, elevator, and fire doors along with other repairs.
• Evaluated, tested and applied a 150 HP efficient grinding system doubling through put and tripling quality.
• Designed multiple mechanical devices and apparatuses to increase employee health and safety and increase the flexibility of the process to better meet customers' demands.

Confidential, South Bend, IN

Plant Manufacturing Engineer/Engineering Manager

• Launched 15k-gallon disperser mixer for $850k in 3 months allowing plant to change from a single shift money losing operation to a 24/7 money making operation. Programmed 15k mixer in Rockwell Factory Talk & Studio, for the HMIs (PC based) and Contrologix distributed controller system and replaced all the VFDs (27) with AB ethernet drives.
• Established multiple R&D measurement and production equipment not only in the plant but also in the corporate labs. Improvements targeted product quality, uniformity, cycle and launch times.
• Routinely investigated customer complaints, determined root causes and applied short and long-term process corrections to short term mitigate and longer term eliminate the offending challenges. Areas included but not limited to product contamination associated with maintenance activities, machine wear, customer site conditions, and operator procedures including 6S implementations, product packing and delivery to customer, new product launches, and product quality improvements. TPS Lean Manufacturing tools applied to drive home the results.
• Facility, project & maintenance budget management developing and controlling the bottom-line.
• Helped establish and comply with ISO, QS, EPA, NFPA, NEC, OSHA, and city and state regulations.
• Wrote training materials and trained operators and maintenance crafts on many work instructions and procedures.
• Maintained the facility, utilities, security, communication, and grounds. Established 37 IR camera system across fiber optic server link including motion and door entry.
• Designed and applied 8 leak free chemical, inline, dynamic, mixing systems saving over $2 million annually.
• Refurbished and renovated electrically and mechanically all the machinery and their associated systems.
• Engineering management all projects using engineering, maintenance and contractors.
• Environmental - Developed, modified and managed the EPA and IDEM Title V.
• Designed, plant managed and implemented chemical processes, mechanical, electrical, software, controls and facility improvements.
• Responsible for hiring, terminating, training, mentoring and administering performance evaluations along with routine participation in or leading focus teams.
• Staff level plant manager directing all process and facility improvements including doubling electrical, air, fire protection, security and communication.
• Designed, managed and established, multiple state of art R&D test and manufacturing equipment to shorten the sample to industrial quantity produced products.
• Modified a winding machine and associated racking saving our largest and most profitable customer.

Confidential, Auburn, IN

Senior Engineer/Project Engineer

• Designed and implemented a process effectiveness tool to manage labor and machines.
• Lead focus groups to improve plant's bottom line using Lean Manufacturing Tools.
• Troubleshot the more difficult problems.
• Designed, modified, and implemented most of the plant processes, machines and facility improvements including but not limited to 4 story dual mixing systems, calendars, injection presses, metal fabrication presses, chemical treatment systems, chiller control systems, paint systems, tooling systems, assembly systems, hydro mount manufacturing machines, vibration measurement control systems, plant wide power monitoring and control, plant power structure, plant wide labor efficiency software system, and central stores maintenance, production, and purchasing efficiency monitoring and control system.
• Designed and implemented a lean inventory control system to manage the plant's materials, measure maintenance and operator effectiveness, and consumable goods, costs.
• Applied an ABB robot motor mount assembly system.

Confidential , Ft. Wayne, IN

Project Manager/Engineer/Maintenance Manager

• Designed, managed, and implemented $1.5M+ systems to improve plant's bottom line.
• Assisted in establishing project management guidelines for the corporation. Note key points in any project are the return on investment, acceptance criteria, task and resource establishments, timeline, funding and the post completion analysis (PCA). Typically, 90% of my projects return their original investment in less than a year. Exceptions can be safety, new product launch, R&D test equipment, regulation compliance and maintenance projects.
• Managed a 26-man maintenance group responsible for over 20 acres of a 47-acre plant.
• Corporate project engineer managing and designing all R&D projects.
• Developed and designed varying machines for multiple plants to improve plant productivity.
• Machines and processes included but were not limited to extruders, mixers, calendars, presses, uniformity measurement, conveying systems, unloaders, bias cutters, bead formers, mills, bead assemblers, weighment centers, R&D measurement and prototype systems, tire fabrication, sort, and bar code labeling equipment, machine vision, and varied control, SCADA and HMI systems.
• Successfully in a vendor cooperative effort drove bar coding capacity from a middle 90% read rate to 99.98% in front of a hundred of millions North America automation expansion. Techniques advanced during the year long process were, star burst, circle, and circle bounce scanners, and data reconstruction algorithms.
• Applied multiple machine vision and bar code scanner systems throughout the organization

Confidential, Milwaukee, WI

Design Engineer

• Designed automotive engine critical fastening and test station information tracking systems for GM & Ford US, Mexico and Canada.
• Designed and applied small PLCs and middle size machine vision systems to diverse manufacturing processes.
• Designed and integrated vision and automation controls in automotive, beverage, food, and varied manufacturing plants. Names included P&G, Miller Brewing, Carnation foods, along with Ford and GM.