Engineer Plant

Sun Chang **** E. Winged Foot Dr.

Chandler, AZ **249

***/***-****

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

Manufacturing Engineer with 16 years experience at Ford Motor

evaluating forward model

programs design for manufacturing (DPA5 validations), launching,

implementing and continuously

improving product, and manufacturing.

Areas of Expertise:

MODAPTS and MOST licensed Industrial Engineering, Virtual

Manufacturing Engineering (VME) team center, Six Sigma, Productivity

Improvements, QOS, FPS (Ford Production System - Lean Manufacturing),

New Model Product Launching, 8D,

PFMEA, FMVSS Requirements, Cost Analysis for Tooling, Process, and

Facilities, Manufacturing Feasibility Analysis, Design for

Assembly Validations, Ford New Models Program Milestone, SMF (JIT),

and Error Proofing principles to create world-class

Manufacturing processes.

Professional Experiences

Goodyear Tires and Rubber Co, Union City, TN - Plant Industrial

Engineer 2009 - 2010

. Developed operators output standards in mixing department.

. Conducted machine capability studies.

. Led and implemented new continuous improvement project and reduced

processing time from 18 minutes to 13 minutes per each batch.

. Support the plant in achieving an OSHA incident rate objective by

submitting near miss card (1) per week.

Ford Motor Co, Dearborn, MI - Vehicle Operations Final Assembly Mfg

Engineer 2004 - 2009

. Launched 5 new models truck/Van programs at Ohio Assembly Plant and

Twin Cities Assembly Plant.

. Led and developed new model programs Cycle Line Layouts to achieve

Lean Manufacturing Environment.

. Conducted enhanced PFMEA, identified and resolved approx 60 assembly

process, tooling, facilities related

Issues for 2009MY OHAP launch.

. Completed and certified in Green Belt.

Implemented one Six Sigma project per year focused on cost

savings that directly affect the bottom line profit of the

division. First project resulted in 17 S&R TGW $200,000/year

savings through elimination of uncertified battery guns at Twin

Cities Assembly Plant in 2006.

. Utilized extensive Virtual Manufacturing Engineering (VME) Team Center

Technology, identified and resolved

over 300 design for assembly issues for 2012 Ford of Europe

Compact SUV program. (May 2008 - Jan. 2009)

. Managed and led all product/process launch, ergo, error proofing

activities for 2012 Ford of Europe program.

. Led, facilitated, and resolved 2 major NO Build issues and 2 potential

FMVSS issues by utilizing VME Builds,

PFMEA, and conference calls. (2012MY C344)

Ford Motor Co - Ohio Assembly Plant Final Assembly Industrial Engineer

2003 - 2004

. Developed the templates for the roll-out of the 5S, ISPC (In Station

Process Control), and VPOS (Vehicle operations Production Operating

System).

. Conducted over 30 workstations MODAPTS time studies and balanced

lines. Resulted in $800,000 of annual savings

through rebalance actions.

. Implemented Visual Factory and ISPC processes. Result: achieved FPS

(Ford Production System) audit level 5.

. Conducted shop floor kaizen workshops on workstation development to

eliminate non-value added wastes.

Ford Motor Co - FPS (Ford Production System) Coach - Lean

Manufacturing 2000 - 2003

. Implemented lean Manufacturing Team on corporate vehicle operations

team to implement Lean throughout the

vehicle operations assembly plants. Traveled 90% of time to

domestic Ford assembly plants presenting,

training, facilitating and consulting lean implementation

theories.

. Developed JIT Kan ban (pull system and cards system) systems and

reduced inventory by 50% and Lead time by 80%.

. Led a Value Stream Mapping exercise in multi - assembly plants.

Reduced WIP by 50% and product L/T by 30%.

. Developed and implemented 5s. Simple whiteboards to real time shop

floor CIM systems.

. Developed and implemented the Quality Process Mapping procedure which

improved TGW ( Things Gone Wrong)

by an average 30% at TCAP. (2001) Utilized both internal and

external data, Six Sigma tools and techniques,

identified, and implemented permanent corrective actions.

. Trained and coached senior management levels at assembly plants on FPS

(Ford Production System).

. Reviewed plant manager Master Schedule and verify VSM is maintained

and supported per plant Master Schedule.

. Reviewed plant VSM objectives/measurable and capture action items on

plant manager's personal Master Schedule.

Ford Motor Co. - Vehicle Operations Final Assembly Industrial Engineer

1997 - 2000

. Maintained forward model programs direct labor standards.

. Dispositioned current model programs engineering changes for Final

Assembly

. Developed forward model direct labor estimates for Redbook programs

with manufacturing engineers and

facilities engineers.

. Evaluated direct labor requirements for all capacity planning studies

initiated by the Manufacturing Business Office.

. Reviewed all inquiries for cost savings projects, line speeds, fixture

capacities and direct labor requests.

. Supported vehicle operations manufacturing engineers and MBO, i.e.,

HPU target and capacity planning.

. Conducted time study and reduce labor. Results: reduced 10% cycle

time reduction, D/L savings of $900,000/ year

at Twin Cities Assembly Plant (1998), $450,000/year at

Louisville Assembly Plant and Kentucky Truck Plant (1999),

$250,000/year at Edison Assembly Plant, Dearborn Assembly Plant,

Kansas City Truck Plant, Michigan Truck Plant,

St Louis Assembly Plant (1999), and $450,000/year at Kentucky

Truck Plant. (1999)

Ford Motor Co. - Kansas City Plant (F150) Final Assembly Industrial

Engineer 1994 - 1997

. Maintained daily direct labor manpower budget

. Conducted time study, verified production line speeds, and review and

resolve ergo issues with UAW leadership.

. Conducted and maintained O.S.H.A. standards in terms of facilities,

tooling, machine, and environment.

. Managed manufacturing operations for Trim department, time study,

workstation set up, tooling and etc.

. Supported new models launch activities, set up workstations, tooling,

facilities, and QPS/OIS/JSA.

. Delivered labor tasks. Met labor tasks each year.

Vickers Electromech, Wichita, Kansas - Electronics R&D Engineer

1991 - 1994

. Analyzed and modified of electronic programs.

. Developed electronic component testing procedures per F.A.A.

guidelines and specs.

. Functional tested of aircraft electronic and avionic parts. Documented

repair procedures.

. Designed aircraft fuel sensors, fluid sensors, support prototype

build, conduct environmental testing, and release.

Ford Motor Co., KC, MO - Co-op Industrial Engineer

1989 - 1990

. Verified production line speeds.

. Assisted in manpower reduction projects.

. Conducted time studies and reallocate operators allocations.

. Updated plant layouts (CAD) and incorporate facilities and tooling.

. Prepared O.S.H.A. inspections.

Education: Bachelor of Science in Electrical Engineering (BSEE)

The Wichita State University, Wichita KS

Honors: National Deans List, elected to Tau Beta Pi and Eta

Kappa Nu Honor Society,

Golden Key National Honor Society

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