Engineer Manager

+

Lee Tibbitts

*** ****** ******* ** ****** AL *5244

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

Tel: 1-205-***-****

I offer a unique combination of the entire Manufacturing Experience; I have

gained all of my experience from the ground up through dedication and

commitment.

. Plant Operations

. P&L

. Plant Expansion

. Engineering Management

. Tool room Management

. Maintenance Management

. New Machine acquisition

. TS - Certification

. ISO - Certification

. CT-Pat - Certification

. R&D new process improvement

. Continuous Improvement

. Facility Management

. Security Management

. Fixture Design

. Staff Training

. Process Problem Solving and improvements

. Research and Development of new Machinery

. Customer and Vendor Interface

. Specializing in New Facility Start up.

. Kaizen implementation

. JIT and pull systems

. Product improvement through supplier interface

. Setting up action plan and targets for new program/product launch.

. Setting up lean processes within an existing production environment

. Maintenance Management

Employment

Flex-n-gate Alabama February 2008 to present

Manufacturing Engineering Manager

I am head of multiple departments which are

Engineering/Maintenance/Facility/Security/Kaizen/New Business/Plant

Acquisition and expansion (Building/Machinery etc.) I also take the role as

Plant Manager when needed. Meeting all production requirement and business

goals. New program launch from all aspects and securing the future growth

of the facility.

Highlights and achievements

. The reduction in downtime with existing Products.

. Setup complete P.M program for all machine centers with aggressive

schedules

. Setup Continuous Action Plans for the plant driven by OEE.

. Set up a Perishable Vendor Spreadsheet for repeatability with all

consumables through purchasing.

. Setup detailed database of all plant contractors on hand, available

through plant intranet.

. Setup detailed database with a detailed of all Maintenance issues as

well as an on line Work Order System which the entire facility

utilizes.

. Program launch of multiple vehicle platforms Honda Pilot and Nissan

platforms as well as Mercedes new model.

. TS and ISO as well as C-TPAT implementation with 100% implementation

success and certification.

. OEE improvement through engineering action plans with tracking data to

support all improvements through visual management both on production

floor and office.

. Plant wide 5S improvements which are tracked monthly and reviewed by

management during management review.

Company Assets : 10 plastic injection mold presses from 100ton to 3000ton,

1 x 1000ton Tandem line with 3 x 600ton automatic, As well as a 800 ton

Auto, 600ton and 400ton manuals.

Multiple weld cells with 4 times flex welding assembly cell. Multiple C-

frame welders and resistance weld cells. Multiple soft side assembly's

including full tier subs. 4X Moto man dual robot high speed Mig welding

cells.

Ogihara America Corporation May 2007 to February 2008

Engineering Manager

I was employed to launch the new Freight liner program for Ogihara. I was

also employed eliminate all class A scrap costs and come up with press

efficiency improvements. Ogihara provides both large class A and b-class

stampings for Mercedes and Nissan. Ogihara provides Mercedes with 80% of

the M-class, R-class and X-class. This company is Tier 1 to a number of

companies including GM, FORD and CHRYSLER. Manage all engineering programs

and plant C.I's and new machinery acquisitions etc.

Company Assets: 2300 ton IHI Tandem (5 press line up); 2000 ton IHI Tandem

(5 press line up); 2700 ton dual ram transfer press; 300,000 sq ft Assembly-

Flexy cells robotic welding; UT-weld destruct; 5000 sq ft CMM facility.

Prince Metal Stamping June 2006-May 2007 (1 Year contract)

1 Engineer/Tooling/Maintenance Department Manager

Working for a Tier 1 Supplier to Honda, Toyota, Mercedes, Nissan and the

North American Big Three for their High Strength Automotive components, my

duties are to supply the customer with a consistent product of the highest

quality. In order to do this duties are varied in my day-to-day activities,

which include:

New tooling buy off and tryout, all Engineering Changes and Cost

reductions. Set up Action plans that are sister to Preventative maintenance

programs as well as day to day tooling breakdowns. I am also responsible

for tooling Continuous Improvement goals set by the Corporation as well as

all sub contract work and shut down schedules and weekend overtime and

budget goals. I also set and do all Employee evaluations and Promotions

Decisions based on performance.

Highlights and Achievements

. The reduction in downtime with existing Products from 9% to 6% in the

last 6months.

. Setup complete P.M program for existing Tooling

. Setup Continuous Action Plans for the Tooling Department

. Set up a Perishable Vendor Spreadsheet for repeatability with all

consumables

. Setup detailed database of all plant contractors on hand, available

through plant intranet.

. Setup detailed database with a detailed of all tooling issues as well

as an on line Work Order System.

. PPAPP16 new tooling Offloads for the facility as well as buys off from

outsourced work from Contract Build shops!

2 Company Assets: Assets Associated with this Facility were 400T-2500t

Automatics, 2500tTandem Lines that were five press lineups. All lines were

automated completely. Press beds were 240" -150" Press Manufacturers were

Verson, Rovetta and USI and Danly as well as Bliss. The Facility also 3

automated welding Cells (IMAX) Complete Blanking Line With Pneumatic Knife

Tooling.

1 Gestamp North American Nov-2004 to Aug 2006 (2 Year contract)

C.I/Tooling Engineer

Worked for the company who was a Tier 1 supplier to Mercedes and Nissan,

parts produced were high strength structural under body units. The company

was a high volume supplier. The units were assembled complete and delivered

directly to the customer. MY role within the company was first, a Tooling

Tryout and PPAP coordinator. I was then offered the Plant Tooling Engineer

position for the new Transfer Line. Unfortunately, the line did not

materialize due to other capital investments. I was then offered my

position as Tooling Kaizen (C.I) Coordinator. My role was to reduce down

time in the press shop environment and improve product flow through lean

manufacturing and Kaizen workshops.

Highlights and Achievements

. Introduced new lean process to the press shop environment with a

visual and positive pull system.

. Inventory reduction, Blanks and coils and consumables

. DuPont STOP training program, which I managed that reduced incident

rates in the press shop by 42% over a period of a year.

. Designed and manufactured storage systems which enable the use of more

real estate which in the press shop environment is at a premium.

. Designed and manufactured tooling production date stamp change out of

press location with load bearing movable die horses that saved an

estimated 6 hours of lost production time (the press lines were at

$500 a minute for lost time)

. Designed and built a dedicated automation simulator that was used to

pre stage and trouble shoot all automation within the press shop.

. Setup a training matrix for all employees within the facility, Crane

etc.

. Helped Quality with all Engineering changes as getting new levels PPAP

and production ready.

. Helped with Press line trouble shooting and the setup action plan to

eliminate the issues at the root cause!

3 Company Assets: Two SCHULER 2000Ton Transfer Presses, Dedicated 200,000

sq ft Assembly Department.

The Transfers had GUDEL Automation and were capable of 27SPM. Press beds

were 270" x175" Link drive Units. Full Automation Simulator and Blanking

Line with servo isolating Knife Tool

1

2 Thyssenkruppbudd Company-Shelbyville Plant March 1999-November 2004 (3

year contract)

4 Tooling Engineer/ Project Leader

Tier 1 supplier to FORD, GM and Saturn as well as BMW. We provided all

Large Class A panels for these customers as well as the interior panels.

The products were Roofs, Doors, Fenders, Lift Gates and Hoods as well as

complete Class A quarter Panels. We delivered the complete assemblies! The

facility captured all E.C requests in house as well as the C.I surface

improvements required by the customer.

Highlights and Achievements

. Complete Tryout and PPAP of all new Tooling for the following Product

lines, FORD EXPLORER SPORT TRAC, BMW X5 and the new F-150) Face Lift.

. Project leader for the C.I of all existing Assembly hemming Tooling.

. Setup P.M schedule for all assembly product lines in regards to NET

blocks and welding set blocks for consistent repeatability.

. Lead a team to reduce Down Time to a company low of 12% on the FORD

SPORT TRAC frame line.

. Was lead technician in all of the class A die Repairs. (Action Plans

Etc.)

. Setup P.M system for Draw tooling within the Press shop.

. Setup a Consumable Spread sheet.

. Was involved in the setup of complete response safety team on all

three shifts.

5 Company Assets: Three Tandem lines KAMATSU 2500ton Six-press line-up.

One 2700ton SCHULER Tandem line that was also a Six press line up but was

link drive. 300 000 sq ft assembly dept. 110,000 tool room with 8 -1500 ton

tryout presses with one- 2200 double action press. Bolster size was 250" x

170" fully automated rolling bolsters.

1 Toyota South Africa 1997-1999

Tooling Engineer/Tool room Manager

I was recruited for new model try out. After complete try-out and

production in full flow, I was involved in a full automated press line

from ABB. This was a first for the country and I am very proud to of had

this in my career path.

I also did a large part in the engineering changes that were part of

Toyota's culture. I worked closely with the Japanese engineers and

learned a great deal in time keeping Goshi, Kaizen, and Kanban etc. All

of which are now most lean companies processes.

1 Highlights and Achievements

. New product Tryout and PPAP of TOYOTA HILUX and CONQUEST.

. Setup PM program for ABB new Automation and storage system

. I was project leader for Class-A surface improvements for our Class -A

line (1A1)

Company Assets: 13 Press lines from large class-A to light and heavy

Gage press shop; plant had everything from 60 ton to 2800 ton Press

stamping capability; Press beds from 60" to 320"

Johnson's Contracting 1994-1998

Contract Tooling Engineer

Build and design of Tooling for DEFY INC, SAB (South African Breweries)

Spec. Tool and Die and a number of different firms. I built new tooling for

a number of years and a lot of appliance jigs and assembly equipment

Defy Appliances Inc 1993-1997

Jig and Fixture Manager

Jig and fixture design

Managed the Assembly Dept. Tooling, Maintenance and Production

New product assembly design and fabrication

Complete revamp of existing assembly tooling and upgrade

Continuous improvement on the general quality of the product

Worked closely with the overseas customers within their requirements.

B.Halstead and Company 1990-1993

Tool, Jig and Die Maker

Apprentice Tool, Jig and Die Maker

Served my Apprenticeship with this great company. I melt with a large

spectrum of the tooling industry such as, progression tooling plastics

gravity fed and injection as well as

Pressure molds. The grounding I received from this firm is incredible. I

received a Distinction in my Trade Exam due to the proper skills I

received from the firm. I cannot thank them enough.

Education

High School - Matric from Port Shepstone High School

Four years of Study (Bachelors Equivalent)- Mechanical Engineering,

Mechanical science, Technical Drawing and Mechanical Mathematics etc.

Certification

Tool, Jig and Die Maker-Metal and Engineering Industries Education and

Training Board

I.S.O 1219 Pneumatics-Toyota South Africa

Plastics Blow Molding/Injection - Plastics Federation of South Africa

TEIKURO - Class - A surface resurfacing and hard chrome replacement.

Lean Manufacturing Simulation - UK Center for Manufacturing (University

of Kentucky)

Certificate of trainer for Over the Over Head Crane, Over Head Crane

Rigging Instructor - N.A.C.B North American Crane Bureau and Crosby.

General Health and Safety Training - N.O.S.A

Industrial first responder trainer - Red Cross

STOP for supervision - Certified trainer by DUPONT.

EPA- Training

OSHA- Full Certification

I have a well developed Managerial and Inter-personal Skill as well as

priding myself in the relationships and chemistry I have with my fellow

colleagues. I am a result driven professional!

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