Engineer Management

John Yager

Phone: 931-***-****

E-Mail: *-******@***.***

Address: *** ******** ****** ****

Normandy, Tennessee 37360

PAINT AND AUTOMATION ENGINEER

Objective: Paint and Automation Engineer with more than 20 years of paint application experience seeking

position in a successful, innovative company in the automotive or automotive trim business.

Summary of August, 2008 – July, 2010…. Batesville Casket Company, Manchester,

TN

Qualifications:

Finishing Engineer

• Responsibilities: Programming ABB paint robots with Ransburg Evolver electrostatic spray guns

and bells to color-coat and clear-coat metal burial boxes.

Responsible for managing paint flows and mixes from a centralized. Temperature controlled bulk

supply system.

Supervise crew to maintain parts washer, conveyors, air make-ups, ovens, and sludge treatment

equipment and chemistry.

Daily reporting to management on defects, and cost

Work with paint suppliers for quality improvements and cost reduction activities.

November, 2006 – August, 2008….. Honda-Lock Company, Inc. Bremen,

GA

Paint Specialist

• Responsibilities: Programming Fanuc, Kawasaki, and ABB paint robots to paint automotive class

“A” finish on plastic mirror housings, door handles, and other exterior trim parts.

John Yager, 931-***-****

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• Accomplishments: Served as Project Engineer to build a new $10,000,000 automated, prime, base,

and clear class “A” paint line. Successfully launched the new line with ABB Robots, Ransburg

Evolver Electrostatic applicators, and Ransburg 2 component paint mixing systems. The paint line

also included a 7 stage washer, Infrared, and gas convection cure ovens. Humidity and temperature

were controlled to +- 3 degrees and 3% humidity.

Developed a low cost conductive coating application process for the plastic parts to highly increase

transfer efficiency and save paint.

Doubled transfer efficiency on the old paint line color paint process by further automating the

reciprocators to control stop points and adding more efficient electrostatic spray guns.

November, 2004 – November, 2006 …. Murakami Manufacturing,

Campbellsville, KY

Paint Automation Engineer

• Responsibilities: Programming Kawasaki and Motoman paint robots on “2 class-A” automotive exterior

mirror paint lines.

Research and development of electrostatic application equipment to optimize finish quality and reduce cost

by increasing paint transfer efficiency on non conductive plastic surfaces.

Work with paint supplier, equipment suppliers, and paint rack fabricators to maximize resistivity and

conductivity of raw materials and plastic mirror bodies.

Troubleshoot problems with robots, ABB and Ransburg electrostatic Bells, Ransburg electrostatic paint

guns, reciprocators, gear pumps, conveyors, paint booths, and materials.

Develop and write work instructions and TPM schedules for all paint line equipment. Submit capacity and

cost study reports to top management. Conduct transfer efficiency studies to determine costs and track

improvements. Submit business plans to track productivity and defect reduction. Train supervisors, new

operators, sprayers, maintenance and technicians. Train quality inspectors on defect recognition, causes, and

cures.

• Accomplishments: Eliminate all hand spraying on one paint line by reprogramming paint robots. Increase

pieces per shift from 600 to 1,000. Successful launch of new paint line and ramp up production to 6,000

pieces per day.

November, 2000 – November, 2004… D. A. Inc.,

Charlestown, IN.

Paint Engineer

• Responsibilities: Management of paint department including 2 robotic lines and 1 manual paint line that

painted automotive plastic interior trim parts for Toyota. Responsible for set-ups of all paint equipment and

automation including programming of Kawasaki robots and Omron PLC line controls. Trials and

John Yager, 931-***-****

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troubleshooting material, equipment, application methods, and processes to meet productivity goals. Write

technical and job instructions based on trials to maintain quality products. Train technicians, operators, and

maintenance. Schedule manpower and raw materials based on customer demands. Created and maintained

PM, cleaning and maintenance schedules. Environmental compliance and reporting in an EPA “non-

attainment” area. Waste management.

• Accomplishments: Worked with contractors, suppliers, EPA, and customers for successful launch of 3 paint

lines. Solved many problems with automated application of new water based paints. Maintained a 98.6%

first pass yield and an 80% productivity level.

• Increased transfer efficiency by implementing air assisted airless application system on manual paint line.

• Programmed Kawasaki robots and Omron PLCs to reduce cycle times from 120 seconds per rack to 44

seconds per rack. Increased pieces per rack to further reduce cycle times from 11 seconds per part to 5.5

seconds per part.

• Integrated Kawasaki 7th axis turntable without English instructions. (First in US)

• Designed, integrated and implemented automated cap washer systems to decrease spray gun cap cleaning

down time 10 minutes per hour.

• Developed process and programming for new waterborne metallic black coating with supplier and Toyota.

(First to pass Toyota test specifications). Reduced outsource painting cost from $5.50 per piece to $0.85 per

piece. Painted more than 2,000 pieces per day for new Toyota Camry.

• Key team player in ISO 14000 implementation and approval.

1989 – November, 2000…. Aeroquip Inoac, Fremont, OH, Livingston,

TN

Paint Process Engineer, Supervisor

• Responsibilities included: Set-up of paint related processes and written job instructions to meet QS9000

requirements. Specification and implementation of all paint handling and application equipment. Train

operators, maintenance and TPM technicians in process equipment operations and maintenance. Program

and maintain 6 Kobelco paint robots. Conduct trials, set mix formulations, and spray parameters for primer,

base and clear-coats. Program management of Ford and Toyota exterior trim. Project management of capital

projects, new construction and expansion. Paint quotations for new business. Numerous Kaizen and other

cost saving initiatives. Work with Ohio and Tennessee EPA to acquire new permits and improved reporting

methods. VOC reduction activity.

• Accomplishments… Successful project management of 4 million dollar paint line from concept through

construction, start-up, and full production. Movement of existing programs and launch of new programs to

fill new expansion. Conversion from “hot-pot” 2 component mix technology to automated mix systems.

Design of bulk paint and catalyst storage and dispense systems including nitrogen blanketed Isocyanate

systems. Start-up and programming of 7 paint robots (conventional, electrostatic, and HVLP spray

applicators) also responsible for maintenance and repair of those robots. Design, programming and

John Yager, 931-***-****

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implementation of Allen Bradley PLC controlled automated color change systems. Implementation of new

Fanuc paint robot with electrostatic spray on plastics. Worked with Graco engineers as Beta sight for new

Graco P-Mix II 3K. Implemented 3 P-Mix 3K systems with closed loop fluid control.

Skills

YEARS

SKILL LAST EXPERIENC

SKILLS LEVEL USED E

Hand spray Expert Current 30

Robot Programming Expert Current 21

PLC Programming Expert Current 20

Variable Frequency Drives Expert Current 15

2-K mix systems Expert Current 18

Electrostatic spray guns Expert Current 12

Bells Expert Current 6

HVLP Expert Current 20

Airless Expert 21 years ago 16

Air assisted airless Expert 6 years ago 3

Wet and dry spray booths Expert Current 21

Air make-up systems Expert Current 21

Bulk supply systems Expert Current 21

Color match Expert Current 30

Paint testing Expert Current 21

Cure ovens, gas convection Expert Current 21

Cure ovens, IR Expert Current 2

Defect analyses Expert Current 21

Exterior Coatings Expert Current 17

Interior Coatings Expert Current 4

1-K coatings Expert Current 30

2-K coatings Expert 1 year ago 20

Waterborne coatings Expert 6 years ago 4

Primer/ Base/ Clear

systems Expert Current 17

Parts washers Expert Current 6

Iron Phosphate systems Expert Current 2

Professional 1989 – 1991 Terra Community College, Fremont, Ohio

Development

Highlights Electromechanical Engineering/ Robotics, Flexible Automation

4.0 average, Dean’s list

• Extensive training in Japan and U.S. in paint process, paint formulation, organic chemistry, paint

application and robotics

• Factory training by Kobelco, Kawasaki, Fanuc, ABB, Graco, and ITW Ransburg.

John Yager, 931-***-****

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• Dale Carnegie Management program

• Numerous seminars and supplier training

• Training in TPS, Kaizen, Kanban, and TPM

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