Engineer Injection Molding

WILLIAM W. LEHR

**** ******** *** ****,*.C. *****

abl0uh@r.postjobfree.com cell: 205-***-****

Seasoned, knowledgeable and accomplished Process Engineer/ Manager with expertise in injection

molding, process engineering, quality assurance and lean manufacturing..

HIGHLIGHTS

■ Experience: Offer 20+ years of contributions to supervision, process engineering, assembly lines,

lean, error proofing techniques, mold trials, certifications for TS 16949, ISO 14001, and basic SPC.

Purchase equipment, set up process parameters and train staff for new plant operations.

■ Technical Specialties: Comprehensive knowledge of injection molding including thermoplastics,

thermoset and reaction injection. Proficient with vacuum metalizing, flow and UV cure coating

applications including robotic spray. Experience with robotic unloaders. Familiar with Six Sigma.

■ Computer Skills. PC skills include Microsoft Windows, Office suite and Lotus Notes.

■ Strong Communication Skills: Personable, articulate and an effective trainer, –cultivated effective

working relationships with various department managers and engineering staff. Writes with clarity

and strength, –developed documentation for production machinery, systems and operating

procedures.

EXPERIENCE

Johnson Controls Injection Molding

McCalla, Al

Production Manager Injection Molding - April 2010 – Present

Responsible for the daily operations of the injection molding department in all production activities and

concerns. This injection molding facility is comprised of 53 presses ranging in size from 85 to 3500 tons including

electric toggle and conventional hydraulic models. There are over 435 active molds. Mold changes average 40 -45

per day.

Faurecia Interiors

Fountain Inn S.C.

Sr. Process Engineer Injection Molding – July 2008-February 2009

Responsible for process set-ups, cycle time, product quality, mold changes, molds, material, troubleshooting,

maintenance, and scrap reduction in the thermoplastic molding area consisting of 10 molding machines ranging

in size from five hundred to twenty seven hundred tons. Also responsible for all QS documentation

for molding including all SOP’s and PFEMA. Assisted with Control Plan . Mentor and train Process Technicians.

This plant is a JIT plant to BMW and we averaged 30 mold changes per day.

.

Hella Lighting Corporation

York S.C.

Process Engineer Manager - Hella Lighting Corporation – October 2006 – July 2008

Responsible for managing a team of 9 Process Engineers in the Component Production areas which

included the Thermoplastic Molding Dept., The Vacumn Metallizing Dept., Lens Molding and Coating

Dept., and Thermoset Molding and Coating Dept. Responsible for cost center budgets, capitol invest-

ments,productivity improvements,scrap reduction,and cost improvement initiatives.Acted as a liaison to

other Hella locations. Developed relationships between the Process Engineering Dept. and the “internal

customers” of HLC. Championed 3 major projects with investment costs of nearly $750,000 to upgrade

molding presses, standardize processes, initiate SMED activities, and localize BMC material in the NAFTA

region to improve costs and productivity. Contributed to cost saving projects which resulted in thousands of

dollars of savings.

SL Corporation

Alabama Plant

Sr. Molding Engineer – SL-Alabama- July 2004 –October 2006 New Plant Start-Up

Responsible for process set-ups, cycle time, product quality, mold changes, molds, material, troubleshooting,

maintenance, scrap reduction, and new product launches in the molding area consisting of nineteen molding

machines ranging in size from two hundred to thirteen hundred tons and including thermoset and multicolor

disciplines. Assisted with machine installation and de-bug, trained molding technicians, assisted in developing and

implementing Quality Policies related to injection molding. Sourced supplies, mold repair services, and made

recommendations for mold modifications to improve quality. Successfully launched two new product lines consisting

of thirty two new molds and all related material, equipment, and processes for injection molding.

Guardian Automotive

LaGrange Molding Plant

Senior Process Engineer – Guardian LMC May 2003- July 2004

Responsible for process set-ups, cycle time, product quality, mold changes, molds, material, troubleshooting,

maintenance, scrap reduction, and new product launches in the thermoplastic molding areas consisting of sixteen

molding machines ranging in size from four hundred to twenty two hundred tons. Lead team of three Process

Engineers and six mold setters on three shift operation. Successfully launched six new programs. Filled in as

Molding Manager from June 2003 to November 2003 with full responsibility for productivity, efficiency, quality

and human resources.

Guide Corporation (April 1987 –May 2003)

A $600 million automotive lighting manufacture

Senior Process Engineer – Monroe, La September 2002 – May 2003

Responsible for process set-ups, cycle time, product quality, mold changes, molds, material, troubleshooting,

Maintenance, and scrap reduction in the thermoplastic molding areas consisting of twenty four molding

Machines ranging in size from five hundred to two thousand tons. This also included the lens coaters of

which one is a flow coat, heat cure application and one being a spray coat u.v.cure using robotic spray application.

Launch Engineer – Monroe, La March 2002- September2002

Assist in final set-up, de-bug, and start up of new coating and aluminizing operations to include fixturing issues,

material flow issues and new equipment trials. Lead effort in final installation, debug, and startup of new injection

molding machines, dryers, and Sepro unloaders. Train personnel on new equipment and establish process

parameters on new molds for production.

Senior Manufacturing Engineer – Monroe, La. May 2001 – March 2002

Responsible for process set-up, cycle time, product quality, mold changes, molds and material trials,

troubleshooting, maintenance, and scrap reduction in the thermo set housing molding area consisting

of twenty-thermo set molding machines with robotic unloaders, and all associated molds. Supervise the tool

room on third shift.

Senior Process Engineer – Monterrey, Mexico New Plant Start-up Feb. 2000 – May2001

Managed a team of five engineers in the set up of molding, metalizing, coating, and assembly equipment in a new

manufacturing facility. Implement processing parameters; Conduct training, maintenance, troubleshooting, and

continuous improvement activities.

Lead Process Engineer – Monroe, LA 1998 – 2000

Managed lens molding / coating operations, bracket and nylon housing molding areas. Purchased equipment.

Scheduled mold changeovers, production and maintenance. Set-up processing parameters; wrote procedures;

trained / supervised personnel. Led scrap reduction efforts and quality initiatives.

Manufacturing Engineer – Monroe, LA &Anderson In. 1987 – 1998

Provided technical leadership for housing molding, coating and metallizing, metal stamping and presses, assembly

lines and cells activities for production of composite headlamp units and cross-car fascias. Supervised hourly

employees; oversaw quality, production controls and shipping.

EDUCATION & TRAINING

Business Administration Ball State University – Muncie, Indiana

Business Management Colorado technical University Online

Additional courses, training and professional development include:

2003: Husky Operator / 2000: Nissei Machine Controls / Conair Sepro Robots / 2000: Learning to See:

Visual Management Systems and Lean Manufacturing /

1998: H.P.M. Machine Training / Allen Bradley Pro-SET 700 / 1995: Adept Robots /

1992: Van Dorn Machine Operation / 1991: Bucher Injection Mold Machines /

KEYWORDS

Production manager, manufacturing engineer, molding manager, process engineer, production

supervision, assembly, robots, injection molding, injection mold machinery, coating, metallizing,

equipment installation, equipment maintenance, troubleshooting,lean manufacturing, production

scheduling, statistical process controls, SPC, ISO 9000, QS 9000, TS 16049, safety, compliance, trainer,

supervisor.

REFERENCES AVAILABLE ON REQUEST

Contact this candidate