Engineer Manufacturing

ROBERT BAK

******@***.***

***** *********** ****, ***** ****, IL 60491

815-***-**** (M); 708-***-****

PROFILE

Lean Six Sigma Green Belt Consultant for several major industries

(lighting, aerospace, oil, light and heavy manufacturing) both stateside

and overseas. Achievements include implementation of Lean Manufacturing

Principles, facilitating Kaizen Events, Value Stream Mapping, Plant

Layouts, 5S Organization, Kanban Replenishment Systems, and Production

Management. Ability to motivate teams through hands on approach, driving

process improvements resulting in measurable cost savings. Proficient in

MS Office, Visio, and AutoCad.

PROFESSIONAL EXPERIENCE

TY Inc

Inventory Receiving Supervisor/Maintenance Supervisor, 2010 - Present

. Directing a staff of 16, responsible for the material handling operation,

including receiving, export shipments, and supplying the production

lines.

. Designed and implemented a kanban replenishment system for the production

lines of over 1500 items, resulting in reduced travel time of 50 %,

manpower by 30%, and stock outs by 80%.

. Responsible for maintenance of all material handling equipment, conveyor

systems, and other related equipment.

Kaufman Global LLC

Senior Consulting Engineer, Independent Sub-Contractor (2007 - 2010)

Consultant to Schlumberger, a global company, that supplies tools to the

oil and gas industry.

. Optimized the throughput of the facility by 40% through redesign and

implementation of a cellular plant layout.

. Achieved a 45% reduction in tool refurbishing time through process

improvement kaizen events.

. Implemented 5S throughout the plant, resulting in a safer and more

efficient operation.

. Designed and implemented a demand pull kanban system reducing component

stock-outs by 50%.

Chicago Manufacturing Center

Senior Consulting Engineer, Independent Sub-Contractor (2002 - 2006)

Manufacturing Consultant to several clients in the Chicagoland area.

. Facilitated Lean 101, Principles of Lean Manufacturing, including live

simulation for several clients.

. Through current and future state value stream map executed an enhanced

production process. (Flexi-mat)

. Facilitated process improvement kaizen event which resulted in 50%

increased productivity, 50% reduction in floor space, and 20% reduction

of headcount. (Flexi-mat)

. Reduced set-up time on a 400 ton press from 2+ hours to 25 minutes.

(Olsen International)

Technical Change Associates, Inc.

Senior Consulting Engineer, Independent Sub-Contractor, (1998 - 2007)

Lean Manufacturing Consultant to several clients nationwide.

. Wrote a training manual by documenting the electric motor manufacturing

process. (Rockwell International-South Bend, IN).

. Increased production by 150% through design and implementation of a

cellular plant layout. (Lancair - Bend, OR)

. Ensured a successful manufacturing schedule by implementing a demand pull

kanban system for the manufactured components of a composite airplane.

(Lancair - Bend, OR).

. Designed and implemented new layout of a 300,000 sq. ft. electro-

mechanical fabrication and assembly plant, resulting in a gain of 30%

throughput. (Daybrite Lighting Division of Genlyte Inc. - Tupelo, MS).

. Responsible for start-up of a computer chassis assembly operation,

including equipment specifications, designing work stations, setting up

assembly lines, and providing on the job training of employees in

specialized fixtures, semi-automated riveting, and material handling.

(Palo Alto Products -New Braunfels, TX)

. Facilitated over sixty Kaizen events in a variety of areas including

stamping, machining, set-up reduction, cell design, assembly,

warehousing, and 5S housekeeping.

. Instructed over 500 people in the lean manufacturing principles for

various companies nationwide.

ROBERT BAK, Page Two

DFT Lighting / Forecast (Division of Genlyte Inc.)

Manufacturing Manager (1997 - 1998)

Responsible for 15 direct reports and 65 indirect reports in the daily

assembly, fabrication, and paint/powder coat operations.

Directed the purchasing of domestic and imported components.

. By changing over from an assembly line to cell manufacturing,

increased efficiency by 25% in the first four months.

. Implemented a demand pull kanban system decreasing stock out of

manufactured components by 15%.

DFT Lighting /Forecast (Division of Genlyte, Inc.)

World Class Manufacturing Coordinator (1996-1997)

Responsible for the transformation of the entire manufacturing facility

into a world class operation, through partnerships with on-site consultants

and maintenance staff.

. Analyzed product families, developed process flow charts, and designed

and built workstations.

. Trained operators in World Class Manufacturing techniques, such as one-

piece flow.

. Created a cellular layout of entire assembly area including assembly,

packaging, pre-plate, returned goods, sub-assembly, hardware, and

corrugated area.

. Designed and implemented demand pull system using kanban cards and

designated raw in process stock locations.

. Increased on time delivery to customers by 50% by implementing a

system to prioritize shipments.

. Increased production in the assembly work cells by 75%.

DFT Lighting (Division of Genlyte, Inc.)

Manufacturing Engineer / Project Coordinator (1994 - 1996)

Coordinated transfer of the entire manufacturing facility, including all

equipment and tooling, for over 200 SKUs of residential lighting fixtures

from Lightolier in Compton, CA to DFT Lighting, Elgin, IL.

. Trained machine operators on metal fabricating equipment including:

Amada turret press, press brakes, and punch presses.

. Set up production lines and trained employees in the assembly of new

products.

. Transferred and maintained bill of materials, routings, and drawings

of the new SKUs.

EDUCATION

Bachelor of Science Degree, Engineering Chicago Technical College,

Chicago, IL

Lean Six Sigma Green Belt

Certification Villanova University, Villanova, PA

Proficient in MS Office (Word, Excel, Powerpoint, Outlook), Visio, AutoCad

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