DONALD A. CULL

*** ******* *****

HIGHLAND HEIGHTS, OHIO 44143

440-***-**** * acf2bt@r.postjobfree.com

Degreed Industrial/Manufacturing Engineer with a diverse background in

industrial, automotive, aerospace, and consumer products. Experienced

in all facets of manufacturing from site selection to process design,

capital equipment, tooling, and start-up. Capable of taking your new

product online or helping revamp an older product/process. Well

versed in time studies, plant layouts, tooling/fixturing, process

troubleshooting, mistake proofing, cost reduction and lean principles.

Open to positions that leverage my current experience, allow me to

grow into new areas and benefit the organization.

EMPLOYMENT

SWAGELOK COMPANY - Solon OFC - Sr. Mfg. Engineer, Lean & Industrial Eng.

Dept. (10/06-Present)

Product: Specialty valves and fittings

Responsibilities: Develop and run Lean Program for 63 cell plant. Lean

events included 5S, Standard Work, Setup reduction, Cell Design, Cedac

and Kaizen. Industrial Engineering: Time studies, Layouts, and project

assessments.

Achievements:

Developed Pull System that reduced WIP 41% and cut order processing time

from 8 to 4.75 days

Cut assembly costs by 20% and doubled output over 5 yr. period

Color Coded Lube containers - Ran PFMEA CEDAC that resolved wrong lube

issues, 20% RPN reduction (critical situation for applications such as

oxygen service)

60 Series Ball valve Flex-Cells - Developed concept, gained management

approval and worked as project team member to design and build 4

workcells that could run multiple configurations. Incorporated state of

the art advancements in testing, multiple polka-yokes, and eliminated a

multi-step manual torque process

JOHNSON CONTROLS - Oberlin Plant - Industrial/Manufacturing Engineer (2004-

2006)

Product: Econoline Van seats, delivered to Ford OHAP JIT/In-Sequence

Responsibilities: Lean Implementer, Time Studies (MODAPTS), Control

Plans, PFMEAs, Plant layouts, Equipment design/modify/repair, MP2 PM

program, Product/process troubleshooting

Achievements:

Automated Bench Seat Loader - Ergonomic improvement; automated cell

converged, placed in sequence and loaded product to conveyor;

previously operators manually carried and loaded bench seats

TECHCRAFT SEATING SYSTEMS, div. of Magna Intl. (2003-2004)

Product: Ford Escape vehicle seats. Delivered to Ford OHAP JIT/In-

Sequence

Responsibilities: New Plant Startup - Manufacturing Engineering &

Maintenance Supervisor

Responsible for equipment installation and start-up, Supervise staff of

two Maintenance Technicians, purchase, stock and inventory all spare

parts and MRO supplies for dept, MP2-PM program; Also responsible for

department budget, Safety and Ergonomic improvements, QS9000

compliance, Customer support at Ford plant as required

Achievements: Completed move-in/startup in 3 month time frame, Plant

launched on-time with no customer shutdowns or QR's, launched three

model year revisions in one year

TRV, Inc. - Manufacturing/Quality Engineer (2001-2003)

Product: CNC Machine Shop serving Aerospace and Chemical/Fluid Handling

Industries

Responsibilities: AS9100 - Certification, Procedures, Internal Auditor

Parker Gas Turbine Fuel Systems Division - Self-Release Certification,

PD1000 Supplier Quality Requirements, Lean Manufacturing

Representative

Quality - First Article and In Process Inspection, Gage Control and

Calibration (Gagetrak Software)

CNC - Machining, Programming (Gibbs Virtual CNC), CAD drawings, Labor

and Efficiency Reporting

JOHNSON CONTROLS - Strongsville Plant - Manufacturing Engineer (1995-2001)

Product: Mercury Villager/Nissan Quest Seating. Delivered to Ford OHAP

JIT/In-Sequence

Responsibilities: Tier 1 JIT - heavy emphasis on PM program, spare parts

inventory, contingency plans. Design/build/buy new machines and tools,

Methods, Ergonomics, product/process R&D

Plant Operations:

Unitrim - Three 10,000 sq. ft. Automated Carousel Systems each

incorporating 10 overhead carriers, Fanuc Robotic Spray Adhesive

System, and A-B SLC500 System Control

Simulator - Automated conveyor system converges product from three

assembly lines, places in order and loads into semi-trailer

Major Projects:

Robotic Spray Adhesive System - Cut scrap 20% and reduced equipment costs

$30K/yr. by incorporating better process controls; Material savings

$230K/yr.

Machine Shop - Developed/acquired equipment, training and supplies to

start a Machine Shop. This allowed us to prevent/minimize shutdowns,

provide better support to Production, and start building our own

machines, fixtures and tools in-house.

Custom Assembly Machines - Used my design capabilities to start designing

and building machines in-house. By doing this we were able to get

equipment that was robust, performed properly, and met cycle time and

floor space parameters. Cut new machine costs 70%.

Productivity & Ergonomics - By delivering better equipment to Production,

labor hours, lost time, Workers Comp. And medical costs were all

reduced. Plant earned JCI Gold Safety Award in 1999.

Achievements: Earned JCI Chairman's Merit Award

TRIDELTA INDUSTRIES, INC. - Manufacturing Engineer, Remote Control Division

(1990-1995)

Product: Air switches and controls for spa/pool, safety and HVAC

applications

Responsibilities: Methods, assembly times, tooling (AutoCAD), capital

equipment, and troubleshooting. Also worked as part of the Design

Engineering group on new product releases

Plant Operations: Hydraulic Presses, Riveting, Pneumatics, Ultrasonic

Plastic Welding, Wire Processing, Soldering, PCB Assembly, Adhesives,

and extensive hand assembly

Major Projects:

Plant Improvements - Revamped all equipment on shop floor

Product Design - Initiated improvements for better

functionality/assembly

Pneumatics - Initiated the use of air and air logic as low cost

automation

Route Sheets - Revised to include accurate times, sequences, methods

and costs

Ultrasonic Plastic Welding - Initiated as a fast, efficient, low cost

and nontoxic assembly method

NAMCO CONTROLS - Manufacturing Engineer, Electronic Products (1986-1990)

Product: Heavy duty Proximity and photoelectric sensors for automotive

plants

Responsibilities: Methods, routings, tooling and capital equipment.

Plant Operations:

Electronic Assembly - Surface mount and through-hole, automated and

manual.

Mechanical Assembly - Pneumatic equipment, epoxy encapsulation,

ultrasonic welding, vacuum processing, thermal/burn-in equipment, and

hand assembly.

Major Projects:

18mm Proximity Switch Redesign -Redesigned housing for strength, ease of

assembly and weld slag immunity

HazCom - Achieved compliance with Right-To-Know and SARA Title III as

Safety Coordinator

Routing Times - Cut monthly Labor Variance from 20% to 2% and provided

complete instructions

ALLEN-BRADLEY - Twinsburg, Ohio, Co-Op Production Engr. - Circuit board

assy for PLC's (1984)

MILL ROSE COMPANY- Mentor, Ohio, Draftsman - In-house machines (1979)

EDUCATION

MAYFIELD HIGH SCHOOL - College prep, Machine shop, Vocational Drafting

OHIO STATE UNIVERSITY - Columbus, Ohio, BSIE, minor in Manufacturing,

LAKELAND COMMUNITY COLLEGE - Certificate Program in Electronics, 2

courses

LORAIN COMMUNITY COLLEGE -Programmable Logic Controller classes 1 & 2

CONTINUING EDUCATION / SEMINARS - MODAPTS, SolidWorks, Plant Layout, PLC,

GDT, Flexible Fixturing, SMT, PLC Programming, Ultrasonic Welding

(Plastics), PFMEA, AS9100, GibbsCAM, GD&T, Lean Manufacturing

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