Skilled Mechanical Engineer with 14 years of professional experience
including product development, manufacturing operations, management, and sales.
Diverse background includes ISO Quality System implementation and auditing, Design
of Experiments, supplier development, warranty and failure analysis, Corrective
and Preventive Actions, Lean Manufacturing and Kaizen Blitz, and strategic
planning. Proven abilities as a team leader, creative thinker,
and problem solver. Recognized as detail oriented and
thorough, “hands on”, and quality driven.
2001 – Current Quality Engineer Dealers
Manufacturing Company,
Assisted in implementation of Lean
Manufacturing and Six Sigma principals
· Instructed “Day 1” Kaizen training for shop floor employees in Lean Manufacturing fundamentals.
· Led or participated in over 20 Kaizen events, with emphasis on quality improvements, machine setup reduction, 5S, one-piece flow, visual control, and waste reduction including value stream mapping.
·
Drove quality improvement projects using Six
Sigma elements and the Define, Measure, Analyze, Improve, and Control process. Used
Design Of Experiments to optimize machine operation settings
for repeatability and to reduce cycle times. Evaluated equipment suppliers for
product suitability and support and purchased new equipment and oversaw its
installation. Coordinated operator training in use of new equipment,
established preventive maintenance needs, and wrote technical process instructions.
Initiated and led corrective action
committee to improve product quality and address customer warranty
·
Evaluated warranty failure modes and in-house
rework issues for common symptoms, and analyzed by frequency and severity of
failure. Gathered large cross functional team to take on projects and elect
champions. Chaired weekly brainstorm and review sessions and provided technical
help to other teams.
·
Took over the Corrective & Preventive Action
system. Trained others in problem solving methodologies and brought the
tracking system into an electronic format and set measurables to monitor
effectiveness.
· Launched use of visual management storyboards, and the implementation of Palm Pilots to the machining department for real-time Statistical Process Control.
·
Expanded engine test analysis capabilities by
bringing state-of-the-art testing abilities to the engine dynamometer test cells,
including PLC machine control, and opacity and particulate emissions monitoring.
Managed the Calibration, Receiving
Inspection, and Supplier Analysis functions
· Brought the 3 areas together and into the Quality Department, and created a self managed work team.
· Set up a parts classification program and testing procedures and implemented ANSI Z1.4 and 1.9 standards. Launched and oversaw all engine durability tests, and established a technical team to review results.
· Coordinated supplier approval and development activities. Met with suppliers to redesign products for improved reliability and manufacturability, and to qualify them for additional product supply. Interviewed new suppliers to evaluate their quality systems and innovative manufacturing methods.
·
Brought CAD design abilities in-house and set up
a part numbering system and blueprint library.
2000 – 2001 OEM Program
Manager Dealers Manufacturing
Company,
Managed all day-to-day aspects of the
business relationship with our OE customers
·
Launched all new products with OEM customers, including
Ford Motor Company and Freightliner LLC. Established pricing, set inventory
levels, designed brochures, performed customer surveys, and visited customers and
represented the company at trade shows. Created new business with existing
product lines.
·
Overhauled an engine parts merchandising
department, and doubled sales without increasing overhead.
1995 – 2000 Manufacturing Engineer Dealers
Manufacturing Company,
Worked as a Manufacturing Engineer in a
Diesel engine plant
·
Brought new engine assemblies from development
through their release to the manufacturing floor. Ensured manufacturing
feasibility and identified and implemented new tooling. Trained operators in
special processes and use of new tooling. Created bills of material for
Material Resource Planning use.
·
Conducted time studies and balanced machine and
labor usage for balanced flow and reduced Work In
Process. Designed and implemented specialized fixtures for reduced set-up
times. Created labor routings and set time standards, and put a labor reporting
system in place.
·
Directed the Material Review Board team, and
initiated and participated in corrective actions to reduce rework and lower
scrap rates. Drove product design modifications to increase product reliability
and decrease parts variation entering into and resulting from the manufacturing
processes.
·
Conducted all technical communication with both
our suppliers and our customers.
Performed a major role in a successful
QS-9000 / ISO-9002 quality program implementation and certification
·
Designed corporate-wide system for control and
use of process instructions and product specifications. Created and implemented
Dynamic Control Plans, an Advanced Product Quality Planning checklist, and Production
Part Approval processes. Formed the Approved Supplier List. Trained employees
in use of the quality documentation and managed Temporary Deviations and
Engineering Change Orders.
·
Served as internal auditor for the Quality
Department, and Management Representative for 3rd party audits.
Implemented a Kanban style materials
management system for delivery of components to the assembly lines.
·
Created bills of material lists for all finished
goods and established parts bin sizes. Set up component storage locations
including visual parts identification, and changed the production floor layout
to improve flow.
·
Implemented process instructions and quality
standards. Trained the disassembly, cleaning, and inspection work teams to
become self managed. Eliminated parts outages and reduced department labor by
1/3.
1992 – 1993 Team Leader University
of
Led design team for the wheel, brake, and
suspension system of our solar-powered race car entry in Sunrayce ’93.
·
Used Pro Engineer and ANSYS to design parts and evaluate
assemblies for strength and fitment. Used a lathe and milling machine to
manufacture items in-house, and coordinated with an outside shop for CNC work. Elected
to be one of two drivers in the race event from
1991 – 1993 Technical Aide 3M
Company,
Worked with a Senior Engineer to develop
and release the “3M Hooks with Command Adhesive” product line
·
Performed tests and designed test fixtures to
evaluate product design, material content and construction methods. Used DOE to
set up test variables, evaluate results, and design new tests. Involved with
the product from it’s inception through it’s release
to manufacturing and sales.
2005 Earned Machine Lubricant Analyst certification by Noria Corporation
2004 Earned Lean Manufacturing Trainer certification from TBM Consulting Group
2003 Earned Certified Quality Engineer certification by American Society for Quality
2001 Attended Master of Business
Administration courses at the
1998 Certified Internal Quality Auditor, by
Independent Quality Consultants, Inc.
1993 Graduated with Bachelor of Science in
Mechanical Engineering, from the University of Minnesota Institute of
Technology, with an emphasis on Engineering Design.
Experienced
with Magnaflux and other non-destructive testing, and
the use of lathes,
mills, and other machining centers. Knowledgeable in PC
assembly and repair, automotive maintenance and repair, and automotive
electronics. Hobbies include camping, homebrewing, and photography.