Engineer Project

Robyn Knie

***** ***** ***, ********, ** *****

Cell Phone: 414-***-**** Email: *****.****@*****.***

SUMMARY

Results driven Senior Mechanical-Manufacturing Engineer with solid, hands-

on cross-functional experience in: mechanical design concepts; electro-

mechanical assembly; and electronics packaging. Background includes full

life cycle project management of large structures/heavy equipment design,

(CAD, FEA), product performance testing (OSHA Certifications), gear design

and inspection, CNC operations. Additional experience in electro-mechanical

assembly of NEMA and IEC motor control products, factory design/layout,

production line transfers, new product introduction pilots, manufacturing

process standardization and lean manufacturing ( 5S, Kaizen -Blitz, Quick

Response Cells, Value Stream Mapping).

EDUCATION

Master of Science in Mechanical Engineering - Marquette University,

Milwaukee, WI

GPA: 3.4/4.0, Studies: Advanced Dynamics, Weld Engineering, Failure

Analysis, and Fracture Mechanics, Finite Element Analysis (Ansys),

Vibrations and Dynamic Control Systems, Design for Fatigue. (Graduation Dec

- 2009).

Master of Science in Engineering Management - Marquette University,

Milwaukee, WI

GPA: 3.3/4.0, Studies: Project Management, Failure Analysis and Risk

Management (DFMEA, PFMEA, HASS), Computer Integrated Manufacturing, Six

Sigma/Lean Mfg, Supply Chain Management, Financial Management, Data

Mining/Trend Analysis. (Graduation May - 2012).

Bachelor of Science in Mechanical Engineering - Milwaukee School of

Engineering, Milwaukee, WI

Studies: Dynamics of Machinery, Design of Machine Components, Control

Systems, Composites and Materials Selection, 3-D CAD, FEA, Energy Systems

Design, Thermodynamics. (Graduation May - 2005).

Certifications

SME- Bronze Level Lean Training (2009); AGMA Gear Manufacturing Technology

Certification (2006)

Green Belt Training (2009); ASM International Advanced Heat Treating

Certification (2008), Rockwell Automation Yellow Belt Certification (2011),

Rockwell Automation Black Belt Training (2011)

SOFTWARE SKILLS

SAP R/3P, Catia V5, SolidWorks, Pro/E, Pro/Mechanica, UTS, Matlab, C++,

Algor, Ansys, SmartTeam, MS Office (Project, Word, Excel, Power-point etc).

PROFESSIONAL EXPERIENCE

2010 - Present: Rockwell Automation, Ladysmith, Wisconsin

Global manufacture of industrial automation, power, control and information

solutions

Senior Manufacturing Engineer

o Managed complex to medium complexity manufacturing projects to meet

corporate/business breakthrough objectives and annual plant

improvement priorities based on a strategic deployment plan.

o Developed production processes and standardized work instructions for

production personnel in the electro-mechanical assembly of NEMA and

IEC motor control products including: combination starters and

contactors, pump control panels, motor protection circuit breaker

mechanisms, condition sensing switches and signaling devices.

o Improved production yield loss by 15% by utilizing Problem Root Causes

analysis Lean Six Sigma methods ( 8D, 5 Whys, Pareto analysis,

Fishbone/Ishikawa diagrams, MAAR Charts, DMAIC).

PROFESSIONAL EXPERIENCE CONTINUED

2010 - Present: Rockwell Automation, Ladysmith, Wisconsin

Global manufacture of industrial automation, power, control and information

solutions

Senior Manufacturing Engineer

Productivity Optimization Projects

o Designed assembly jigs and fixtures to improve personnel safety on

production lines and increase ease of product manufacturability.

Reduced work place injury and 'near - miss' incidents by 30%

o Spearheaded a cost-reduction project to reduce the variety of shipping

packaging material. Resulted in a 70% reduction of packaging material

and an inventory cost savings of $150,000 per year.

o Lead scrap reduction blitzs. Developed process flow value stream maps

and rebalanced production lines based on production volumes and

product process matrices. Resulted in streamlined processes that

eliminated non-value added steps, a 25% reduction in floor space and

increased production thorough-put by 20%.

o Project lead engineer for multiple Kaizen-Blitz events to reconfigure

8 production lines in a 20,000 sq ft factory addition. Applied

metrics driven lean approach to determine labor capacities, streamline

production processes and balance production through put, This resulted

in 25% improved line efficiency

2005 - 2009: P&H MINING/JOY GLOBAL - Milwaukee, Wisconsin

Global manufacture of mining equipment: shovels, drills and draglines.

Project Engineer

Diverse range of project management functions in R&D, product performance

testing, machine counterweight/stability analysis calculations,

transmission/gearbox design, and six-sigma/lean manufacturing. Duties

featured supervising designers in product concept design and analysis,

product performance evaluation, developing and implementing lean

manufacturing continuous improvement initiatives.

o Directed a cross-functional team to overhaul a SAP based Non-

conforming material system. Resulted in a restructured, streamlined

process, with a 35% reduction in processing time, developed process

capability KPI's and cleared up $2M worth of inventory backlog of

unprocessed defective parts.

o Coordinated the application of Six Sigma/Lean techniques to modify

existing plant cell layout and oversaw the development of Quick

Response Cells, 5S and Kaizen events for in-house manufacturing, which

eliminated $200,000 of waste, per quarter and improved machine cell

efficiency by 25%. Calculated machine capacities based on forecasts,

recommended and justified capital equipment purchases.

o Successfully managed the Defective Product Salvage Process during high

volume production and an influx of deviation requests from in-house

machining and sub-contractors. Developed defective material salvage

processing work instructions for new engineers and processed on

average, $350,000 in inventory value of deviations per week.

o Spearheaded a product consolidation project and oversaw the design and

implementation of new improved major assembly components of the PH

4100 Series shovels, on to smaller PH 2800 Series shovels, with minor

modifications. The resultant product uniformity reduced field assembly

inventory costs by 15% and eliminated the need to invest $500,000 per

year in new machining set-up and assembly costs.

o Project Leader for the overhaul of existing hoist drum assemblies to

extend service life expectancy by 50% and improve product performance

by improving weld quality and modification of hoist drum design

features.

o Optimized the design of the propel transmission planetary gear drives,

to counteract the effect of plant gear location errors on gear mesh

backlash and static gear tooth loading.

o Formulated hoist and propel transmission rebuild inspection manuals

for all shovel series gearboxes and trained manufacturing and field

service personnel in the application and maintenance of inspection

criteria.

PROFESSIONAL EXPERIENCE CONTINUED

2005 - 2009: P&H MINING/JOY GLOBAL - Milwaukee, Wisconsin

Global manufacture of mining equipment: shovels, drills and draglines.

Project Engineer

o Directed product development and performance testing (DFMEA, PFMEA,

HASS) for various products including: operator cabin Falling Object

Protective Structures (FOPS), operator seat vibration testing and

seatbelt strength testing. Tests resulted in securing OSHA

certifications for the products.

o Formulated whole machine counterweight structural stability analysis

tabulations for PH 4100XPC and PH 2800XPC series shovels. Thoroughness

and accuracy of the calculations provided reliable values to enable

field counter-balancing of shovel machines

2004 EPSI - MASKING & HANGING SOLUTIONS - Menomonee Falls, Wisconsin

Mechanical Engineering Intern - Performed SPC tests on parts, utilized

SolidWorks to develop 3-D designs.

2001 - 2004 CENTER FOR BIO-MOLECULAR RESEARCH AND DESIGN - Milwaukee,

Wisconsin

Undergraduate Research Assistant - Designed 3-D models of protein and DNA

structures using RP RasMol and SolidWorks software and performed FEA on

protein structures using Cosmos. Operated rapid-prototyping machinery (Z-

corp., SLS).

CONSULTING WORK

The following Projects were performed in the capacity of Marquette

University Graduate Student consultant teams.

Six Sigma/ Lean Manufacturing Projects completed as a requirement for SME

Bronze Level Lean Certification.

. North American Clutch Corp. (NORAM), Milwaukee, WI

o Designed three separate cellular manufacturing cells to increase

product throughput during high volume production

o Developed Value Stream Maps for overall processes.

o Identified WIP, process flow restrictions and waste sources.

o Performed a PFMEA evaluation to optimize the efficiency of the

manufacturing cells.

o Outlined recommendations for 5S and Kaizen events.

. Andis USA, Sturtevant, WI

o Restructured and streamlined the Crest Blade Cleaning process,

by eliminating process flow restrictions and identifying water

and energy waste sources.

o Developed key performance indices to track water and energy

usage.

o Recommended load leveling of Blade batches going through the

cleaning cycle based on forecasted production requirements.

. Lucas Milhaupt Inc, Cudahy, WI

o Performed machine capacity resource planning and designed a

Quick Response Manufacturing (QRM) cell to improve overall

production yield.

o Developed spreadsheet model of QRM that allows calculation of

lead times and production yield for a specific production order.

o Performed a PFMEA evaluation on the QRM cell.

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