Robert D. Soucy
**** *** ******* **** ******, Ohio 44060
Residence: 440-***-****, Cell: 440-***-**** E-mail:
*********.**@*****.***
Process Engineering / Manufacturing Manager
Process Engineer and Manufacturing Manager with extensive experience in
engineering and manufacturing fields with expertise leading manufacturing-
based profitability growth. Experienced in day to day manufacturing plant
operations, including on time delivery, quality, labor, inventory
management and materials resource planning. Maximized processing lines for
peak efficiency for product manufacturing. Able to manage large and high
profile projects to successful results.
Leadership, Product, Program Process and Profit and Loss
Supervision, Team and Project Efficiency Management
Building & Coaching Management Improvement
Strategy Product / Process TQMS / ISO Compromise,
Development & Design and 9001:2008 Negotiation,
Execution Development Lean6Sigma Listening,
Communications
Professional Experience
PCC Airfoils, LLC, Wickliffe, Ohio
April 2005 - August 2012
Manufacturing Area Manager
Directly responsible for the steering and management of Thermal, HES Dip
and Setter Block Manufacturing departments; manufacturer of custom ceramic
bodied Aerospace engine components. Established operational policies and
implemented process improvements to ensure superior quality and increased
output. Directly responsible for managing 20+ direct labor associates and
Engineering Co-op students. Implemented coaching and training programs to
develop staff, facilitate efficiency and improve performance. Monitored,
controlled, approved expenditures and evaluated local suppliers for raw
materials, replacement parts and equipment. Ensured adherence to strict
quality control procedures to maintain ISO9001:2008 compliance.
Selected Contributions:
. Led the turn around transformation of departments of responsibilities
from being low-performing into low labor, highly flexible operations; by
driving cultural changes and implementation of basic
foundational/fundamental elements of management
. Delivered bottom-line improvements through standardizing work processes
and leveraging takt time to capture 20% increase in operational
efficiency. Increased productivity from 78% to 105%+ by reducing waste
and increasing manufacturing efficiency.
. Tasked with recruiting, interviewing, hiring, training, coaching,
evaluating, and disciplining or terminating employees.
Process Engineer
Performed engineering work related to planning, devising, and adapting
methods to improve manufacturing.
Managed Injection and thermal processes across all shifts to ensure quality
and customer requirements including: Product and Project Management;
Quality Assurance; Equipment performance and Tooling design. Provided
forecasts and plans. Developed suppliers and vendors. Improved processes
including cost reductions, quality improvements, ease of manufacturing and
ease of operator use. Directly responsible for developing Engineering Co-op
students.
Selected Contributions:
. Netted external customer acceptance on numerous internal process changes
which yielded a lower labor, quicker and more cost efficient product.
100K average annualized cost savings per process change.
. Significant reduction in salvage firing (reprocessing) of product through
final fire operation by implementing stringent contour or form
requirements in the raw or virgin product state (post injection molding).
Projects averaged 30% increase in first time pass through yield which
placed increased quantity of product in customer hands sooner and netted
25K average reduction in labor and material costs internally.
ATI-Ohio/Aviation Product Support
August 1994 - February 2005
Process Engineer
Performed engineering work related to planning, devising, and adapting
methods to improve manufacturing.
Managed assigned Aerospace fan blade cellular manufacturing cells
including: Product research and Development; Project Management; Quality
Assurance; FAA Compliance; Equipment Development and Tooling design.
Improved processes including cost reductions, quality improvements and
streamlining of operations. Developed, trained and coached new and existing
labor associates for cross functioning applications.
Selected Contributions:
. Shadow masking design, development and implementation which netted a
substantial cost reduction in prepping operation for wear resistant
coating application to engine components. Previous method required a
manual application of high temperature masking tape. Improvement to
shadow masking eliminated prepping operation and only required fixture
loading by Plasma Spray Technician. 200K+ annualized plant wide cost
reduction.
. Co-chaired cellular manufacturing cell implementation for streamlining of
manufacturing processes. Overall 50% reduction in turn-around-time which
ultimately netted additional overhaul and repair contracts both
domestically and international.
Unit Manager
Directly responsible for the management of multiple fan blade product lines
that included all operations from receipt to customer return ship.
Partnered with Business Units for developing and utilizing labor associates
globally in all aspects of the business. Established performance
indicators, operating goals, realignment initiatives, productivity
improvements, and cost reductions. Supervised 30+ direct reporting labor
associates in union environment.
Selected Contributions:
. Responsible for the identification and transition of work from in-sourced
to out sourced vendors to reduce total manufacturing costs by 35% and
decreased TAT (turn around time) by 1-2 business days.
. Responsible for 25% cost reduction in abrasive belts, pads and tooling by
globally researching, testing and designing the best fit application for
polishing & finishing processes.
. Proven leadership capabilities in creating formal production operation
plans, developing, training and coaching labor associates with becoming
self-directed workers.
Education
. Lakeland Community College
Associates Degree Coursework
. Lakeland Community College
Six Sigma Green Belt Certification
Qualifications
. ISO 9001 certified internal auditor - PCC Airfoils & ATI-Ohio
. FAA certified repairman - ATI-Ohio
Other
. Familiar with Metallographic analysis:
1. Magnetic particle
2. Dye penetrant
3. X-Ray
4. Eddy Current
5. Ultrasonic
. Knowledge in various welding disciplines:
1. TIG
2. Electron Beam welding
3. Induction brazing
. Molding experience:
1. Injection molding
2. Insert molding