Manager Project
Resume:
MICHAEL L. CHROSTOWSKI
Sunapee, NH 03782
*******.***********@*******.***
SUMMARY OF QUALIFICATIONS
Engineering and Manufacturing Professional with significant multi-
functional experience in a wide variety of manufacturing environments and
industries. Background includes:
. Strong organizational, project planning, and resource management
skills. Department and project budget planning and management.
. Extensive experience in New Product Launch including development of
standardized NPI processes based on APQP methodology and execution
of launch projects in both the cross-functional team leader role and
as a product and process design individual contributor.
Coordination of Customer, Internal, and Supplier activities to
achieve program cost objectives. Utilization of FMEA methodologies
to mitigate risk.
. Extensive experience in Process Engineering including demonstrated
creative thinking and problem solving abilities in support of
corrective actions and/or continuous improvement issues facing
Operations. Utilization of Safety, Quality/NRFT, Delivery,
Productivity, Inventory, and Downtime metrics to prioritize
opportunities, facilitate justification, and demonstrate
effectiveness. Analysis of data to identify root-cause. Areas
within scope have included Product Design, Process Design, Equipment
and Tooling, and Measurement Systems.
. Championing of Lean initiatives in both a Toyota Production System
and Lean / Six Sigma environment.
. Creation and implementation of process control tools including
Performance Monitoring, SWI's, 5S, Control Plans, Quality Standards,
SPC, and Poke Yokes.
. Equipment and Tool design and modification through installation,
qualification, and on-going support.
. Foreign and Domestic Supplier and Vendor qualification.
. Plant Engineering and Facilities Management including environmental
compliance responsibilities. Predictive Maintenance implementation.
. Proficiency in AutoCad, MSOffice, and MSProject.
. Beginner level comprehension of Mandarin Chinese. Currently
studying with help of language mentor.
PROFESSIONAL EXPERIENCE
Velcro USA, Inc., Manchester/Somersworth, New Hampshire
Manufacturer of variety of hook and loop fasteners - three manufacturing
locations in New Hampshire. Manufacturing processes include textile
weaving & knitting, needle punched non-wovens, and plastic extrusion based
products with coating, rotary cutting, and other conversion processes.
Customer base is medical, military, industrial, automotive, and consumer.
Operations Engineering Manager (8/09 to 11/12)
. Functional Manager for Equipment and Process Engineering Groups
including staff supervision, performance management, work assignment &
review, organizational alignment, and budget control.
. Provided ongoing process and equipment engineering support to New
Hampshire Operations. Provided satellite support to global teams.
Responsible for leading effort in scrap reduction.
. Implemented standardized project chartering, management, and tracking
methods to facilitate prioritization, justification, resource allocation,
and scope & cost containment.
. Implemented standardized IQ/OQ/PQ process.
. Managed process qualification and commercialization phases of New
Product Introduction.
. Directly managed qualification of Asian tool supplier including tool
design, supplier process development, inspection requirements, and
finished product qualification. Resulted in ~$800,000 annualized
savings.
. Provided equipment engineering support to Velcro global operations
including transfer of 2 extrusion lines from NH to China facility.
. Directly managed highest NH scrap driver corrective action to reduce
scrap by ~$30,000/month.
Timken Aerospace & Super Precision Bearings, Lebanon, New Hampshire
Division of Timken Bearings. Precision bearing component
manufacturer and assembler. Customer base is primarily Military
applications.
Engineering Section Manager, Lean/Six Sigma Leader (10/05 to 5/09)
Functional Manager for Reliability Engineering and Maintenance Groups.
Includes staff supervision, performance management, work assignment and
review, organizational alignment, and budget control.
Provided equipment engineering support for Aerospace bearing plant.
Processes included machining, heat treating, rough & precision grinding,
and bearing assembly.
Coordinated complex PM's, repairs, overhauls, installations, and equipment
moves.
Enhanced the existing PM system with performance monitors, visual work
instructions, and "pitch route" lubrication and fluid replenishment carts.
Identified ring finishing process families and designed cell layouts to
enhance flow.
Utilized value stream mapping to establish strategic inventory
supermarkets with pull signaling.
Established daily manufacturing management methods with metric review and
activity tracking.
NSK Steering Systems America, Inc., Bennington, Vermont
NSK Steering Systems America is a wholly owned subsidiary of Japan based
NSK Corporation specializing in the design and manufacture of steering
columns for the automotive industry. Customers included Toyota, Honda,
Nissan, Ford, and Daimler-Chrysler. Processes include assembly, welding,
machining, swaging, and tube forming.
Manufacturing Manager (1/04 to 10/05)
Manufacturing Manager of Production, Manufacturing Engineering, Lean
Manufacturing, and Maintenance Departments.
Lead monthly production resource planning and daily production achievement
and counter-measure reviews.
Reviewed business plan and prepared Manufacturing department annual
budget. Tracked and managed costs.
Under mentoring of a Toyota Production System (TPS) Sensei, championed
continuous improvement efforts with focus on waste reduction,
profitability improvement, and assurance of quality and safety standards.
Applying TPS methodologies, achieved annualized productivity increase of
~25%, NRFT reduction of ~40%, Downtime reduction of ~25%, PPM reduction of
~65% while supporting sales volume increase of ~20%.
Tools utilized included TPS line monitors, PFMEA's & Control Plans, DOE,
productivity based production planning & staffing, 5S line organization,
Standard Work charts & combination tables, QA network, and various
analysis and resource prioritization tools.
Member of Honda Minivan TPS improvement team.
Manager of Programs (APQP) (4/02 to 1/04)
. Manager of Project Management group responsible for new product
launches.
. Provided program leadership and direction to Ford Escape cross-
functional team of product engineers, manufacturing engineers,
quality engineers, buyers, and materials management personnel to
insure customer quality, price, and timing goals are achieved.
Interface regularly with customers on program status, activities and
issues.
. Responsible for definition and implementation of standardized
Advanced Product Quality Planning (APQP) system insuring effective
and efficient product design, production processes, and quality
controls in compliance with customer-specific requirements and
company standards. Some specific APQP elements include: design &
process FMEA, process flow & value stream definition & analysis,
control plans, statistical process control, and PPAP preparation &
submission.
Troy Mills, Inc., Troy, New Hampshire
Troy Mills was a manufacturer of composite non-woven textile goods
primarily supplying to the filtration, automotive interior trim, and
specialty felt markets. In addition to needle-punched manufacturing of
rolled goods, processes included thermoforming, laminating, calendering,
fiber dyeing, and saturation bonding.
Plant Engineer / Launch Engineering Manager (11/95 to 4/02)
Functional manager of Launch (New Product) Engineering, Maintenance, and
Facilities Departments.
Project manager (directly or through staff) for all new product launches
and processing equipment installations, redesigns, and overhauls.
Provide daily process engineering support addressing quality &
manufacturing issues. Lead all Customer driven cost reduction activities.
Insured plant regulatory compliance associated with air, water, and
hazardous waste emissions. Established a standardized facility
environmental compliance program.
Primary customer contact regarding new product development, quality
concerns, and/or cost reductions incentives and provided technical support
to Sales/Marketing group in evaluating feasibility of new programs,
products, or markets.
Completed design, build, and qualification web adhesive laminating
production line.
Project Manager for design, installation, and qualification of $1M loom.
Program Launch Leader (6/94 to 11/95)
Project Engineer responsible for planning, organizing, engineering, and
integrating new or revised thermoformed product launches from concept
through end of production.
Managed over 15 program launches including Taurus/Sable, Winstar,
Expedition, Escort, and Grand Am.
Primary responder to customer concerns on design and quality issues.
Coordinated plant resources with customer requirements to ensure launches
proceeded within strict time, quality, budget and product costing
constraints.
Utilized CAD, surfacing, and solids modeling software in development and
verification of part and tool designs.
Managed all tooling, fixturing, or program specific equipment activities
including quoting, sourcing, design and direction of fabrication.
Developed tooling and process improvements (utilizing traditional
experimental design techniques) to support production efficiency and cost
reduction efforts.
Executed all Advance Product Quality Planning (APQP) requirements
including development of product specifications, control plans and FMEA's,
machine setups, and operating and inspection procedures.
Plant Project Engineer (6/92 to 6/94)
Designed, analyzed, and directed fabrication and installation (both in-
house mechanics and outside contractors) activities for assigned plant
(textile and converting) equipment improvement projects.
Completed over 40 major production line equipment redesigns,
reconfigurations and installations.
Executed all troubleshooting activities and initial manufacturing setups
and qualifications.
Provided on-going engineering support to maintenance staff related to
equipment performance or breakdown issues.
Olaf Soot Associates, Greenwich, Connecticut
Olaf Soot Associates was an engineering consulting firm specializing
in the custom design of movable structures and other specialty heavy
equipment. Mr. Olaf Soot is the firm Principal.
Project / Mechanical Design Engineer (1/86 to 5/92)
. Mechanical Design Engineer responsible for the design and
preparation of detailed drawings and contract documents for
project mechanical systems.
. Performed field and shop testing and troubleshooting of
designed equipment - resolved issues as needed.
. Served as primary contact for clients, vendors, and fabricators
in order to expeditiously coordinate design, design review,
fabrication, and installation activities to assure project
completion within strict time frames.
. Conducted extensive static and dynamic engineering analysis of
critical design elements.
. Analyzed system performance, proposed for approval redesign
solutions of electrical and hydraulic power/control systems to
address issues. Implement approved solutions.
. Firm projects included:
- Earthquake simulating tram platforms for Walt Disney World's
Catastrophe Canyon special effects attraction.
- Roof-mounted pivoting racks for the mounting of spot and
floodlights to illuminate the front fa ade of NYC's Grand
Central Station as part of the client's area revitalization
project.
- Hydraulic operated access platforms for Walt Disney World's Body
Wars and Star Tours motion simulator attractions.
- Cable suspended manned DJ platform installed at Disney World's
Pleasure Island facility.
EDUCATION / CERTIFICATION / TRAINING
University of Connecticut, Storrs, Connecticut 1985
B.S.M.E. - Mechanical/Materials (Metallurgy) Engineering
Double Major
Seminar Training:
. Toyota Production System - Directly mentored by 30
year TPS trainer.
. Lean/Six Sigma Green Belt.
. Taguchi Method of Experimental Design - Worcester
Polytechnic Institute.
. Introduction to Design of Experiments - Worcester
Polytechnic Institute.
. Basic Statistical Process Control - Worcester
Polytechnic Institute.
. Poke Yoke - Worcester Polytechnic Institute.
. 8D Problem Solving Technique - Nichols College.
. Basic and Advanced Thermoforming - University of
Wisconsin, Milwaukee.
. Failure Modes & Effects Analysis, Measurement Systems
Analysis, Advanced Product Quality Planning (APQP),
Production Part Approval Process (PPAP) - Automotive
Industries Action Group
Related Activities:
. Hold State of Connecticut Engineer-In-Training
certification.
Contact this candidate