Christopher Harkai

Qualifications Summary:

Twenty years of experience in a manufacturing plant.

!

Twelve years painting plastic parts and 4 years of spray PU and open pour foam utilizing ABB 5402, ABB 5400, Staubli

!

RX130, Fanuc M-2000IB, M-20IB, M-16IB, P50, P200, P500 robots and Motoman HP-20.

Twelve years supervisory & engineering experience in a union environment responsible for 30 – 80 employees.

!

Automotive Specific Systems including: SAP, SFR, OHSIM and CMMS (IMS5/IMS7)

!

Experience with Ford Payroll and Maintenance Systems such as TWOS, MAXIMO and e-Time.

!

Knowledge of Ford and General Motors Exterior and Interior Quality Standards.

!

Color experience using X-Rite, MacBeth Light Booths and BYK Equipment.

!

Defect Analaysis Experience: Dirt, Craters, Sags, Mottle, Splays and Part-Substrate.

!

Casting processes and materials management for a tier I automotive suppliers including, but not limited to:

!

! Robotic open and closed pour poly foam operations (FRIMO and HENNECKE)

! FRIMO (STAUBLI) Robotic Wet Score Machine

! GFM Automatic Laser and Ultrasonic Score Machine

! Door, IP Rotary and Trim Fixtures

! Spray PU door, IP systems

! Molding operations utilizing 3250T UBE presses

! Experience with resins such as TPO, TEO, PC/ABS, Dylark, Spray PU and others

Factory Automation Suite (FAS) & Rockware Software.

!

Superb comprehension of fluid dynamics using FLUENT flow analysis software.

!

Thorough knowledge of pump mechanics and the ability to rebuild small and medium sized industrial pumps from

!

replacing o-rings, packings, ball check valves, fluid seals, bushings, and shafts.

Experience using (backflushing, nozzle cleaning/replacement, and membrane replacement) on a five stage HALO RO

!

(180 gpm) part washer system. We used this system in the paint booth for rinsing final stage parts.

Excellent knowledge of maintenance on robot systems, conveyors & their various components.

!

Complete knowledge of 1K and 2K, prime, monocoat and base/clear paint systems.

!

Experience with paint vendors such as PPG, BASF, Red Spot, Rohm & Haas/Nippon, Dupont and others.

!

Solid knowledge of paint testing, including chemistry and paint kitchen knowledge.

!

Secondary tooling design including paint fixtures for both current and upcoming product.

!

Excellent problem solver and able to make decisions quickly under pressure& adaptable to a variety of situations.

!

Trained in lean manufacturing utilizing both the six sigma model and kaizen.

!

Identifying new process methods that improve production yield and cut excess scrap.

!

System Optimization, Implementation and follow up for maximum cost savings.

!

Complete knowledge of quality specifications and rejection criteria as it pertaining to painted parts.

!

Thorough knowledge of documentation for TS-16949 Quality Procedures, and PPAP process, Control Plans, FMEA’s

!

and Process Analysis.

Safety procedures involving volatile chemicals, conveyor systems and robotic machinery.

!

Mastery of all robotic programming using Robview and Paintworks Pro 2.0.

!

Programming Fanuc and ABB controllers for various applications.

!

Basic programming in Unix, Linux, and Visual C++.

!

Engineering design software knowledge of CATIA, Pro-Engineering, CFX, and IDEAS.

!

Excellent PC skills including Microsoft Office Suite with versatility on either a Windows or Mac.

!

Accomplishments:

Supervise multiple operations (often concurrently): Spray 1, Spray 2, Spray3, D258 RIM-Trim,East Molding Press.

!

Improving conveyor speed from 9 ft/minute to 17 ft/minute, achieving a 47% increase.

!

New carrier configuration implemented from 750 parts per day to 4500 parts per day, achieving 600% increase.

!

Switched ad-pro from single head non-electrostatic to dual head electrostatic increasing transfer efficiency by 30%.

!

Incorporated two additional robots to base and ad-pro to add additional programming flexibility.

!

Added new mica booth with four robots to paint monocoat and tricoat with the possibility usage as a degrade.

!

Creative usage of “paint robbers” to eliminate tip drips and reduce scrap.

!

Original throughput 75-80%, currently running 90-95% and still improving.

!

Dirt rejection rate was originally 6-8%, currently at 0.3-1.6% and still improving.

!

Downtime rate was originally 10-15%, currently at 4-6%, and still improving.

!

Automated robotic dry ice blast tool cleaning, which reduced our tool maintenance overtime by over 30%.

!

Auto-quip 1.5cc per rev disposable gear pump to a rebuildable bar mag DLC GP series 3cc per rev gear pump for an annual

!

savings of $73,800.

Flat Rock, Michigan 48134 cell 734-***-**** acfl11@r.postjobfree.com

Christopher Harkai

Professional Experience:

August 2012 – Present

Faurecia, Saline, Michigan

Process Engineering Supervisor, Spray PU and Paint Systems

• Total Productive Maintenance Trainer (TRM)

• Trainer for new Engineers

• New Equipment Implementation

• Troubleshoot paint spray systems

• Trouble shoot open pour PU and foam systems

• Efficiency and cost analysis

• Vendor Interface for new and improved products and processes

MSX International (Plant changed hands in 2012 as Faurecia purchased the ACH facility and I was hired direct)

Production Supervisor/Process Engineer, Automotive Component Holdings Plant (ACH) March 2010 – August 2012

• Spray 1, 2 & 3

• D258 Door Rotary And D258 Floor tools (RIM-TRIM)

• East Molding Press Area

• D258 Door, Console and IP Assembly Area

• 22X/228 Door, Console and IP Assembly Area

• Trainer for new Supervisors & Engineers

NYX International, Inc., Livonia, Michigan

Paint Engineering Manager January 2009 – February 2010

! Set-Up and Maintenance of two complete paint systems

! Interior PC/ABS & ABS

! Directing and programming robot process configurations for continuous improvement

! Inspection and maintenance of equipment for maximum efficiency

! Vendor interface for new and improved products and processes

! Troubleshooting and crisis management

Norplas Industries/Magna International, Northwood, Ohio

Process Engineer June 2008 – October 2008

! Paint Operations Management (due to budget cut salaried lay-offs)

! Exterior TPO

! Directing and programming robot process configurations for continuous improvement

! Inspection and maintenance of equipment for maximum efficiency

! Quality assurance and documentation

! Vendor interface for new and improved products and processes

Plastech Engineered Products, Inc., Romulus, Michigan

Process Engineering Supervisor April 2001 – June 2008

! Exterior TPO/ Paint Operations Management (Out of Business/Bankruptcy 2008)

! Directing and programming robot process configurations for continuous improvement

! Inspection and maintenance of equipment for maximum efficiency

! Oversees forty manufacturing personnel, training and development of team members & reviews

! Quality assurance and documentation

! Vendor interface for new and improved products and processes

Johnson Controls, Taylor, MI

Production Supervisor March 1994 – December 2000

! Lead manufacturing personnel with production and process optimization projects

! Directed lean management and JIT quality initiatives for customer quality excellence incentives

! Training and development of personnel, encompassing process operations, quality control,

performance reviews & career advancement initiatives in accordance to the company’s vision

Education:

Washtenaw Community College

Course of Study: CAD Design in UNIX environment w/ Pro-E and Catia

Flat Rock, Michigan 48134 cell 734-***-**** acfl11@r.postjobfree.com

Christopher Harkai

Belleville High School - 1990 Graduate

Flat Rock, Michigan 48134 cell 734-***-**** acfl11@r.postjobfree.com

Contact this candidate