STEPHEN M. GREGORY

773-***-**** • acdo05@r.postjobfree.com • 40W012 Wellington Way • Geneva, IL 60134

Sr. Manufacturing Engineer

Accomplished Manufacturing Engineer with broad-based expertise and a track record of excellence in managing major comprehensive projects in areas including machining, washing, deburring, and assembly. Excellent project management skills dedicated to executing designs with great emphasis on quality, safety, and cost-savings. True problem-solver able to identify issues on production floor and design or modify tools address needs. Analyze machine utilization, balance flow, recommend and implement process improvements. Utilize and apply lean problem solving tools such as 5Y and fishbone diagrams.

Project Management

AutoCad Proficient

PLC (AB SLC500, Control Logix)

6 Sigma Green Belt Certified (2010) 6 Sigma Principles & Tools

Motoman Robot Training

Industrial Ergonomics Training

Safety/Ergonomics: Implemented two cutting tool manipulators to address the highest safety risk for an operator-performed task of handling cutting tools greater than 40lbs.

Cost/Design: Commonize cast features on a family of machined components to eliminate setup changeovers.

Cost/Throughput: Utilized aggressive milling process to improve cycle time resulting in 15% throughput improvement.

Quality: Added validation requirement to control plan for part probing process, created standard work procedure, and clear reaction plan improving quality and reducing scrap by 10%.

PROFESSIONAL EXPERIENCE

TUTHILL PUMP, Alsip, Illinois

Sr. Manufacturing Engineer, November 2013 – Present

Responsible for providing root cause analysis using lean tools and analysis for internal and external 8Ds. Production responsibilities three assembly cells and one machining cell. Participant in machining cell K

Creating all standard work for machining cell gradually incorporating a one piece flow strategy.

Implementing a DC torque tool to create a one step process for rundown and controlled final torque. Sound level is reduced from >95dB (air tool) to <75dB.

Torque arm being implemented in conduction with DC tool to eliminate hand/arm strain typically associated with assembly operation.

Torque tool controller will error proof and ensure all bolts are torqued on each pump in a 4,6 or 8 bolt batch mode.

CATERPILLAR, Lower PowerTrain Value Stream, Montgomery, IL

Sr. Manufacturing Engineer, November 2008 – November 2013

Responsible for Lower Powertrain CNC machining for differential case and center housing assemblies utilizing six horizontal machining centers, two vertical lathes and three horizontal lathes. Created and maintained a process control plan, standard work, SFMEA, and PFMEAs for respective areas. Specify and / or improve the tooling, fixturing, gauging, packaging requirements needed to carry out the manufacturing plan.

Ran 1.1M project implementing a new 5 axis, 800mm pallet machining center and procured all cutting tools, gauges and work holding, resulting in 20% cycle time reduction.

Lead in Value Stream Assessment to define and remove machining time from constraint processes. Performed tool usage analysis to provide focus on 15% reduction of milling cycle to level burden load across three machining assets.

Provided solution to highly repetitive manual deburr process by locating a back chamfering tool to

eliminate need for manual tool and minimizing safety risks for operators.

Identified and proposed engineering dimensional changes during New Product Introduction (NPI) process to commonize workholding for two high volume P/Ns reducing setup frequency, and commonize critical diameters to minimizing gauging costs. 15k cost avoidance.

BORG WARNER TRANSMISSION, Bellwood, IL

Sr. Manufacturing Engineer/Project/Lead Engineer, Aug. 1999- Aug. 2008

Developed and managed the installation of new production lines including production machinery with focus on increasing productivity through tooling/machine improvements, line balancing in multi-process cells, and new operator training.

Specified and installed a 1.5M Hot Die Bonding cell for LuK Automotive Systems torque converter product line and

installed 1.2M hot die bonding cell for a GM six speed transmission friction element.

Coordinated production line move from Frankfort facility and implemented multiple levels of improvement in areas of

tooling, controls, error proofing and safety.

Specified and installed 2nd Separator Plate finishing line; capital investment is 1.4M producing 45-50K plates/day for

Toyota/Asian Warner.

Specified and installed 1st Separator Plate Finishing line in Borg Warner – North America; 1.8M capital investment

producing 40k plates per day.

Wrote appropriation, purchased and lead the installation of an auto-feed deburr/polish and dry production line for

friction plate cores.

Increased production throughput of a “bond and size” production cell for GM by 15% through die re-targeting and

total cycle time reduction while maintaining Cpk=1.33 thickness capability requirements.

Coordinated installation of five automatic thickness measurement machines in “bond and size” cell eliminating “bottleneck” of manual thickness gauging to increase production throughput.

Designed new sizing tools, replacing existing ten-year-old tools to eliminate root cause of customer complaints from

sizing operation.

CHICAGO METALLIC CORPORATION, Chicago, IL

Manufacturing Process Engineer, October 1994 - 1999

Roller die and tool design, coordination and implementation of new roll forming lines, production line trouble shooting and new\revised progression roller die trial and pre-production runoff. Setup department in prove-out phase of new roller dies; tool room in standardizing die sharpening procedures, R&D in load testing and material investigations.

Project Engineer

Responsible for six complete production lines. Designed all roller die, cut off and pierce die tooling for three of the six lines. Coordinated implementation of hydraulic and electrical components of production lines.

• Increased X-Tee line speed from 110’/min to 145’/min by implementing DC control cutoff system.

• Redesigned production roller die progression to run problem .008 galvanized steel and worked with Setup department to prove out design.

• Created data collection sheets for operators to help identify and combat sources of roll adjustment downtime.

EDUCATION

B.S. - Aerospace Engineering, St. Louis University - Parks College of Engineering and Aviation, Cahokia, IL

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