Paul Berna

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

Hudson, NC *****

586-***-**** cell

acv7x2@r.postjobfree.com

PROFESSIONAL PROFILE

During my 24 years of management, supervisory experience and leadership responsibilities, my three divisional engineering teams included mechanical, industrial and electrical engineers. Responsibilities included a “contract” engineering staff that was designated to companies such as Delphi Automotive and American Axle & Manufacturing. My plant experience, management skills and leadership consisted of “Hands On” supervision of the tool room along with the maintenance departments for (3) three shifts per day and (6) six days a week.

My background consists of strong “Hands On” management in applications, R&D, product development & design, tooling development & design, manufacturing, quality and maintenance including a strong interface with the automotive, appliance, office furniture, Nuclear, DoD and DoE marketplace and understand the high demand for product cost reduction and higher quality. Contribution with General Motors and Ford Quality Improvement Committees - (ISO – 9001:2000 & ISO - 14001:2004) Department of Defense (MIL-STD 1916:1996) & the Department of Energy.

EDUCATION & CERTIFICATIONS:

BSME (MSU)

Journeyman Tool and Die

Member: SPE, SME, AWS

PROFESSIONAL WORK EXPERIENCE:

Transbotics Corporation

Chief Operations Officer (COO) – 2/1/12 -

Designers & Manufacturers of Custom Automated AGV / AGC Systems

Overseeing and coordinating the following of Corporate Managers (Design, Project Management, Production / Assembly, Test, Service, R&D) to ensure operations are meeting goals and expectations.

Drive Warranty cost lower with Managers and improve our ISO process and procedures.

Strategic Vision and Agility.

Leadership and Organization.

Capacity Building.

Continuous Improvement per our ISO process.

Flanders Filters Corporation

Engineering Manager – 10/19/09 - 1/1/12

Designers & Manufacturers of Fabricated Nuclear Customized Filtration Systems

Oversee total engineering functions of a 32 person department.

Robotic development for Air Filter & Containment manufacturing.

Implementation of divisional work cells (“5S” methodology) in the manufacturing area that eliminated excessive labor costs, improved product quality and higher product throughput that generated a yearly cost savings of $ 1,369,500.

Duperon Corporation

Value/Streamline Product-Process Manager – 1/12/07 – 11/26/08 (Lay-Off)

Designers & Manufacturers of Storm and Waste Water Treatment Equipment

Product development and redesign of a Flex-Link and also changed the investment casting source (poor quality) that generated a yearly cost savings of $ 98,900.

Product development of a new style Drag Chain Conveyor that eliminated costly customer break downs and generated a yearly gross income of $ 860,400.

Implementation of divisional work cells (“5S” methodology) in the manufacturing area that eliminated excessive labor costs, improved product quality and higher product throughput that generated a yearly cost savings of $ 106,950.

Lakeside Design & Engineering, Inc.

Director of Engineering – 11/21/01 – 12/23/06 (Owner retired-health issues & sold the Co.)

Manufacturing Engineering Design, Project Management & Consulting Services

Developed a mold-on-web technology that eliminated total manual assembly of the product (insert molding, bulb/reflector/switch/handle assembly, E-test and packaging) that generated a yearly cost savings $ 787,000.

Machine development and design of a new automated part (C.V. joint) transfer and assembly system (lean manufacturing) that eliminated excessive labor costs, improved product quality and higher product throughput that generated a yearly cost savings of $ 612,650.

Product R&D regarding a redesign of a rear differential housing for a major Tier II automotive supplier to facilitate the elimination of two complex machining operations that generated a yearly labor and tooling cost savings of $ 1,370,350.

Trim Trends, Inc. –

Engineering Manager - 7/5/00 – 11/6/01 (Lay-Off due to economic conditions “9-11”) Metal Stamping, Roll Forming, Metal Fabrications, Robotic Welding & Automated Assembly

Developed three automated welding cells including replaceable tooling and the implementation of lean manufacturing techniques that took the place of the manual welding operations for an automotive base frame unit. This cell eliminated excessive labor costs, improved product quality and higher product throughput that generated a yearly cost savings of $ 1,565,000.

Incorporated an automated quick die change system for two Bliss hydraulic presses. This system generated an additional 18.3 hours of machine up-time per week.

Established, maintained and supervised a Lean Manufacturing Quality system for the stamp, roll form, assembly, welding, tooling and maintenance departments. This quality implementation consisted of SPC, Six Sigma, Kaizen and “5S” Methodology including the use of PFMEA and FMEA documentation.

Established and implemented a “Hands On” Proactive, Predictive and TPM (total productive maintenance) system for the maintenance department. ISO – 14001:2004

Dynamic Corporation, Inc. –

Director of Engineering – 12/5/96 – 6/30/00 (Left because of company downsizing)

Manufacturing Engineering Design, Project Management & Consulting Services

Established, maintained and supervised an engineering department that consisted of three divisional engineering teams that included mechanical, industrial and electrical engineers. My responsibilities also included a “contract” engineering staff. The first year of operation generated a gross income of $ 2,856,000 after capital expenditures were paid for.

Established a long term contractual agreement with two major Tier II automotive suppliers for contract engineer services and engineering projects that generated a gross income of $ 5,850,000 in the first eighteen months of operation.

Developed, designed and implemented a laser sighting system that was used for the location of machines and upper beam mounted part conveyance systems for facility layouts. First used in a 1,300,000 square foot manufacturing company located in Buffalo New York.

Lakeside Design & Engineering, Inc. –

Engineering Manager - 7/7/94 – 12/2/96 (Left because of Company ownership issues)

Manufacturing Engineering Design & Consulting Services

Developed, designed and manufactured specialized test equipment for a major government agency that was used in the development of braking and steering controls for a tactical tracked vehicle.

Developed, designed and manufactured a dual inverted robotic weld system. The automatic part locator and hold down system accepted thirty two individual parts that were welded together by three hundred & thirty two puddle welds.

R.W.C. Inc. –

Program Manager - 2/12/91 - 6/27/94 (Lay-Off due to the downswing of appliance sales)

Automated Metal Forming, Welding and Assembly Equipment.

Interfaced with a world recognized appliance manufacture regarding a R&D program pertaining to the new front load cloth washers and dryers that you see in the market today. The program consisted of the development, design and prototype build of the outside product framework configuration. The project utilized “Design for Manufacturing” techniques.

Incorporated SPC, Systematic Problem Solving and PFMEA practices in the development, design and manufacture of a fully automated production system that produced appliances such as refrigerator, washer, dryer & dish washer pre painted and textured sheet metal formed frame structures.

Outsourced all of the machining and subassemblies. This generated faster product turnaround, better quality and the elimination of assembly rework. Generated a yearly cost savings of

$ 364,500

APPLICATIONS: Engineering / Tool room / Manufacturing / Quality / Maintenance / Quoting (tooling, machines, components) / Cost justification / Machine design and specifications / Customer interface / Manufacturing process improvements / AutoCAD / Drawings / Solid Edge / Programming on P.L.C.'s, and Fanuc robotic controllers / Interface primary and secondary equipment / Controls and specification interface / Capital expenditures & justification / Financials / Robotic: adhesive application, assembly / Cost estimating: machining, grinding, forgings, stampings, plastics / Design and Development of automated AGV / AGC systems.

RESEARCH & DEVELOPMENT / PRODUCT DEVELOPMENT & DESIGN: Water & waste water equipment & purification / Design for manufacturing / Black box development (i.e. 40th Anniversary Corvette "logo") / Automotive: front windshield, electric steer / Electronics: LED lighting / Machine: storm & waste water / Robotic application: painting, assembly, Glue application /Injection molding: medical devices, insert molding, two shot / Blow molding / Heavy machinery: drive systems, heavy castings & machining / Thermoforming / Window encapsulation / Rubber molding / Hydro-Forming: copper, brass, aluminum / Thermoforming: tooling, product development / Metal forming / Wood application: cabinets, displays, furniture / Conveyors: chain on edge, drag chain, walking beam, screw, belt, incline / Casting: product development, Vision: quality / Destructive test / Non-Destructive test / Robotic applications / Automotive transmission test / Automotive drive train: axles, gears / Compactor – washer / Functional test equipment / Product flow & development calculations / Fasteners: plastic, metal.

TOOLING & MACHINE DEVELOPMENT / DESIGN / IMPLEMENTATION: Robotic EOAT / Robotic applications / Metal & Steel Fabrications / Tooling follow-up / Rotary die cutting / Thermoform / Blow molding / Die casting / Cold heading / Brazing / Thread roll dies / Steel rule dies / Roll forming / Piercing / Bending / Stretch bending / Blanking /Skid mounted equipment / Plastic molding: medical devices, automotive decorative trim / Thermoforming: tooling, product development / Hydro-Forming: copper, brass, aluminum / Rubber molding / Plating fixtures / Assembly / Window encapsulation / Automotive drive train: machining fixtures, castings, assembly / Machine layout and design / Conveyors: chain on edge, drag chain, walking beam, screw, belt, incline / Welding: manual, robotic – automotive, structural / Hot and cold metal forming / Rotary Die Cut & Steel Rule Dies / Stamping dies: deep draw, progressive, pre & post notch (roll forming) / Gauges: non contact, air, dial, electronic / Heavy machinery: drive systems, heavy castings & machining / Welding fixtures: manual, automatic location, product assembly / Robotic: adhesive application, assembly / Fasteners: plastic, metal.

MANUFACTURING: Laser applications / Machine tool: work cells (5S) / Test / Gauges / Fabrication & Assembly operations: metal, plastic, hand tools, medical, adhesive / Machining: hobbing, grinding, milling / Roll forming / Blanking / Stretch bending / Conveyors /Castings: investment, ductile, gray iron, aluminum / Heavy machinery: drive systems, heavy castings & machining / Hand tool development - design / Skid mounted equipment: power generation – high pressure washer systems, Hot and cold forgings / Stamping operations / Die cast / Window encapsulation / Plastics molding: automotive decorative trim / Thermoforming / Blow molding / Hydro-Forming: copper, brass, aluminum / Fasteners: plastic, metal / Robotic applications / Wood application: cabinets, displays, furniture / Painting: metal / plastic - E-coat, mask, spray & wipe, class 100,000 / Welding: robotic, manual / Decorative automotive trim / Thermoforming: tooling, product development / C.V. joints / half shafts / Case Harding / Grinding / Forging / Secondary operations: Hot stamp, Pad printing, Mask painting, Vacuum metalizing, Hard chrome plating: plastics / Robotics / Robotic: adhesive application, assembly

QUALITY: Lean manufacturing / Six Sigma / “5S” Methodology / Kaizen / Systematic Problem Solving / Gauge R & R / GD & T / FMEA / PFMEA / SPC / Vision systems / ISO – 9001:2000

MAINTENANCE: Proactive / Predictive / TPM (total productive maintenance) / ISO – 14001:2004

My background lends itself to providing cost-effectiveness along with the responsibility of many projects from beginning to end with the ultimate goal providing my employer with the best for less. I am very budget conscious without sacrificing quality or needs. I also have strong analytical, problem-solving and organizational skills. Achieved excellent HR consultative skills with a strong track record of achieving results along with excellent written and verbal communications and ability to share knowledge at appropriate levels of the organization.

ADDITIONAL ACCOMPLISHMENTS:

American Management, Metal Forming and Tooling & Production magazines published articles nationally on “robotic work cells” that I developed, designed and implemented.

(Articles will be furnished upon Request)

Development of a Gearless Angular Rotary Drive which can be applied to the manual and power applications of transmitting positive, zero backlash, constant velocity angular (90 to 179 degrees) rotary motion without the use of bevel gears, universal joints, belts, chains or any flexible means .

Delivered the opening speech for “Robots – 12” at the Cobo Hall Conference Center in Detroit, Michigan. Discussed the implementation of robotic work cells into small production companies and the long term effect regarding product quality, throughput and actuality of costs and payback of capital expenditures.

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