Engineer Project

Gerald J. Fronczak

*** ******** ******* ****: 716-***-****

Williamsville, New York 14221 E-Mail: ******@***.***

Professional Summary

Results-driven Manufacturing / Industrial Engineer with over twenty years

of diverse, progressive manufacturing operations experience successfully

building/leading high performance teams implementing improvements in

production processes, productivity, safety, inventory, quality and product

cost.

Improvement Methodologies:

Continuous Process Improvement, Lean Manufacturing, 5S, Value Stream

Mapping, TPM, Visual Factory

Functional Experience:

Manufacturing Management, Team Facilitation, Project Management

Selected Skills:

. Standard Work/Methods Development . Capital Equipment

Justification .

Kanban Pull Systems

. Single Piece Flow Cellular Development . SMED Setup Reduction

System . Kaizen Teams

Professional Experience

Columbus McKinnon Corporation (CMCO), Amherst, New York 2006 - 2009

Manufactures a broad line of Material Handling Products with divisions

around the world and sales of $650 million.

Process Improvement Manager (2006 - 2009)

Provided Project Management leadership for electric chain and wire rope

hoist divisions facilitating and implementing key corporate initiatives

with emphasis on the utilization of Lean Manufacturing Principles.

Developed comprehensive project justification analyses, engineering

solutions, project planning workbooks, timelines and capital budgets.

. Completed a $550,000 Workplace Organization Project at facility in

Michigan.

- Implemented 5S Methodology, ergonomic applications, and strong

overall emphasis on Safety.

- 23% reduction in OSHA recordable lost work time injuries and rate

the first year.

- 25% lead-time reduction in the Fabrication Department.

- Reduced floor space by 20% in the Machine Shop Departments totaling

18,000 square feet.

- Improved air quality by filtering mist/dust at the source and

installing a fresh air make-up system.

- Organized tooling, fixturing and WIP storage applying visual tools

and systems.

- Realized a significant reduction in absenteeism directly related to

the improved work conditions.

. Introduced, facilitated and implemented a Machine Shop Setup Reduction

program utilizing SMED principles and techniques. Realized a 32%

reduction in changeover time on initial targeted work centers.

. Generated project plan and obtained approval for a $1.65 million cost

reduction initiative utilizing Lean Manufacturing Principles to

consolidate 4 hoist divisions into a single "Gear Center of Excellence".

. Successfully implemented Gear Outsourcing Project that targets high

volume, simple designed gears.

American Axle & Manufacturing, Inc., Buffalo, New York 1994 - 2006

OEM manufacturer of driveline systems and forged products for the

automotive industry.

Senior Lean Productivity Improvement Engineer (2004 - 2006)

Planned, developed and implemented Lean Manufacturing principles for all

operations. Developed direct and indirect labor budgets, provided direct

labor analysis, developed plant layouts utilizing AutoCAD, and provided

value engineering/value analysis support for new product cost estimates.

Maintained plant capacity data base and worked on a corporate team to

deploy corporate-wide improvement strategies.

. Designed, developed and justified the reprocessing and material handling

of Pinion and Ring Gear manufacturing. Converted high volume batch

processing into lean, single piece flow work cells. Reduced lead-time by

67%, realized $1.3 million annual labor savings. System became the

corporate benchmark.

. Led numerous Kaizen events in our plants continuous improvement efforts.

. Integrated an accumulating walking beam conveyor replacing an existing

handling system into our automated Axle Shaft Line resulting in a 6%

productivity improvement for the line.

Gerald J. Fronczak Page 2

Professional Experience (continued)

Manufacturing Engineering Supervisor / Program Launch Coordinator (2001 -

2004)

Supervised 4 Industrial Engineering/Layout Engineers responsible for

purchasing and installation for new material handling equipment to

ergonomically comply with existing/new production processes. Provided

Project Management leadership directing cross-functional teams to launch

new production systems.

. Successfully launched a Gear-Set Magnesium Phosphate Coating System, a

Heat Treat "Load to Alloy" Material Handling System and a "MCE Steering

Linkage Assembly Line" on-time and under budget.

. As Project Leader, coordinated multiple vendors personnel on the

successful integration and installation of the complete Axle Shaft

Processing System; total project cost of $24.5 million.

. Completed plant wide departmental "scrolling" layouts for 1.2 million

square foot facility.

Industrial Engineering Supervisor (2000 - 2001)

Direct supervisor of 4 Layout Engineers, 7 Industrial Engineers and 1

Material Handling Engineer. Coordinated the Industrial Engineering plant

support for the initial launch of the GMT 360/370 Platform which was a

complete newly designed Axle for the Trailblazer and Envoy SUV.

. Developed and maintained a plant wide Direct and Indirect Labor tracking

system for 1200 employees.

. Developed and Implemented an Excel data base to generate annual

Direct/Indirect Labor Budget's.

Productivity Manager (1998 - 2000)

Coordinated manpower utilization and operational analysis. Drove

productivity improvement meetings with Maintenance, Production Supervisors

and Hourly Associates focusing on cost, quality and delivery.

. Improved GMT-800 Steering Linkage Assembly Line throughput 36%.

. Coordinated the rearrangement of the steering linkage machining and

assembly operations incorporating Lean Manufacturing. Reduced floor space

required by 17%, part travel distance by 35%, part touches by 27%.

Increased productivity by 16% and achieved labor reductions totaling

$675,000 annually.

Continuous Improvement Workshop Coordinator / Trainer / Facilitator (1996 -

1999)

Industrial Engineer (1994 - 1998)

Coordinated and facilitated monthly workshops consisting of cross-

functional, union and management personnel. Introduced Lean Manufacturing

Principles and Workflow philosophies resulting in a headcount reduction of

49 and significant improvements in cost, quality and delivery. Provided

Industrial Engineering plant support focusing on time studies,

methods/cycle time improvements, and productivity initiatives.

. Differential Case Assembly Project - Rearranged workplace with ergonomic

and method improvements effectively eliminating double handling of

components. Realized annual labor savings of $750,000.

. Carburizer Throughput Improvement Project - Reduced WIP and improved lead-

time by 12%. Developed new methods eliminating the critical ergonomic

high risk stress motions.

. Lasalle Carrier Workshop - Improved process time 35%. Reduced direct and

indirect labor. Reduced machine downtime by implementing a scheduled tool

change program and operator PM program.

. F-Car Throughput - Improved methods and workstation layout reducing the

total labor content 31%.

. Implemented Ratio Specific Gear Processing Standard Work Methods and Work

cell rearrangement; realized $1.3 million annual total factory cost

savings.

Harmac Medical Products, Inc., Buffalo, New York 1993 - 1994

Industrial Engineer

Leroy Industries, Inc., LeRoy, New York 1992 - 1993

Manufacturing /Tooling / Production Engineer

ITT Aimco, Amherst, New York 1985 - 1992

Senior Industrial Engineer

Education

State University of New York College at Buffalo, Buffalo, New York

Bachelor of Science - Industrial Technology

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