MICHAEL L. CHROSTOWSKI

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

Sunapee, NH 03782

603-***-****

ab8yhs@r.postjobfree.com

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