Project Manager Engineer
Resume:
Jack Edling
abli55@r.postjobfree.com Fenton, Michigan
Education:
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. BSIE Purdue University
. MBA University of Michigan, Flint
. Eastern Michigan University & Mott Community College- Non-degree -
Education
Additional Training:
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. Delphi Production System (Delphi version of Toyota Production System -
Dr. Yamada on site), Value Stream Mapping - Womack, Design for
Manufacturing, Jonah Course - Eli Goldratt Institute, New Haven
Connecticut
. Delphi/GM in-House Training - Flow Manufacturing, Synchronous
Manufacturing, Value Analysis & Value Engineering, Competitive
Manufacturing, Lean Equipment Design, Supermarket Planning & Delivery
Systems, Workplace Org & Visual Control, Small Lot, Leadtime
reduction, Changeover Reduction, Ergonomics, Ergonomics Strain &
Sprain Training, Employee Relations, QS-9000, Failure Mode & Effects
Analysis (FMEA), Synchronous Systems, Advanced Statistical Process
Control, Engineering Statistics, Value Analysis/Value Engineering
(VA/VE), MTM GM Std Time & Motion analysis, Materials Management,
Labor Relations, SAP-Labor Routings & Production Versions, SAP-Cost
Estimating, ABC Costing, Excel, Word, Outlook, Project, DataEase,
AutoCAD Beginning & Intermediate ('97) - 2005 is latest version of
AutoCad I have used, Lotus Notes, Facilitator Skills, Time Management
Professional Summary:
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. Delphi Production System (Toyota Production System), Lean
Manufacturing, Synchronous Manufacturing, Value Stream mapping,
Material Flow Planning, 5S, Kaisen, Changeover Reduction, Kanban,
Theory of Constraints, Coupling-Decoupling, Line Balancing,
Participant and Leader of VA/VE Teams, Cost Benchmarking, Cell
Manufacturing, Cart Delivery Systems, Kitting Systems, Plant Layout,
AutoCad 2005, Work Sampling, Cost Estimating, Time Study, Standard
Hour Systems, Costing Systems, MBA Thesis - Comprehensive Oil Filter
Make vs Buy Analysis - presented to the Product Team
. Familiar with following Processes: Assembly, Material Flow analysis,
Stock Rooms, Delivery Systems - carts, tuggers & fork trucks, 100-1000
ton Molding, 10-700 ton Stamping, Circuit Board Assembly, Kilns,
Powdered Metal, Machining, Heading, Casting, Electro-coat Dip Paint
Systems, Powder Paint Systems, Infra-red Curing, Plating, Washing,
Ceramics, Welding, Wire Benders, Tube Bending, automatic screw
machines, Heat Treating, Degaussing, Magneform, Rubber Diaphragm
Curing, Warehousing, Automated Material Handling, Box making, Paper
Folding, Plastic code storage, dryers and dispensing systems, Sheet
Metal coiler/de-coiler/slitting, spring bending.
. Familiar with the following Product Lines:, engine machining and
assembly, instrument clusters, electric and mechanical fuel pumps,
modular fuel pump, sending unit & reservoir assemblies, spark plugs,
mechanical tachometers and speedometers, air core gages, oil and air
filters, sheet metal air cleaners, plastic air cleaners, cruise
control servos, circuit boards, air meters, mass airflow sensors,
automotive assembly.
. Detailed Lean Self-Assessment available upon request
Professional Experience:
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CKGP/PW Contract Project Engineer - Penske Logistics
6/10 - 7/10
Sequencing Center Launch Team - 7 week Contract Assignment
. Served on a start-up team for Ford F-150 Sequencing Center
. Performed Layout implementation, troubleshooting hi-lo driver flow and
site engineering support
Seeking Work
10/09 - 5/10
George S May Company International
7/09 - 9/09
Staff Executive - Consultant
. Small business consulting - specialization in process improvement and
cost identification, reduction and control.
. 100% travel - had to resign due to short term foot problem.
. Did not return due to self-imposed travel restrictions for personal
reasons.
Laid off - Seeking work
11/08 - 7/09
. Delphi dropped all contract engineers and Acro had no work
Acro Corp - Contract Industrial Engineer
11/05 - 10/08
. Spark Plug - Ergonomic support, capacity data management, layout
development & support, formulating and tracking the build out and
stock room storage plan to optimize build location and warehouse
sizing, defined janitor job elements using industry standards &
customized elements for site standardized work - reduced 3 out of 8
janitors in adjacent plant.
. MRA - Modular Reservoir assemblies - assembly & stock room
consolidation and relocation for site consolidation, assisted in
redevelopment of material handling plan, Implemented 10+ new Kanban
systems - 2 days & $60K inventory reduction, relocated/consolidated 2
MRA assembly lines, led teams to rebalance 4 assembly lines,
maintained change management process (GES), maintained /updated
routings (SAP) input new standard hour labor routings - approx 1200,
maintained construction task team list and coordinated work, relocated
/consolidated offices for Spark Plug shut down and later MRA
fabrication (approx 75 people), member of site lean consolidation team
to relocate & consolidate 75,000 sq ft of manufacturing and stock
rooms, developed all layouts on AutoCad 2005, Led Indirect Material
crib consolidation team, led and developed team to implement new line
and balance for MRA assembly, assist in equipment relocation and
transportation to Mexico. Served on Suggestion committee
. Supervisor - Cathleen Hale, Industrial Engineering & DMS Manager 810-
257-5721
. (DMS is the Delphi Mfg System which is Delphi's version of TPS, Toyota
Prod System)
Lide Industries
1/08
Independent Consultant (over 2 week Christmas Break while working for Acro
at Delphi)
Independent Consulting Job at Lide, Industries
Steel storage tank manufacturing - Mexia, Texas
Bobby Lide: 254-***-****
. Identified 10+ minutes per tank potential savings opportunities in
fabrication and material handling flow improvements.
. Other opportunities were identified in labor measurement, workplace
org & visual control, trailer assignment & scheduling and roller table
fab & assembly concepts reducing material handling labor.
. Customer expectation was at least 1 minute per tank savings.
. Some ideas were partially implemented when I left.
TPT Total Productivity Team Experience - Contract Consultant
9/05 - 11/05
Project Manager
. Worked for TPT Total Productivity Team - LLC in Detroit as part of a
large team of IE's hired by Ford sent to 13 Visteon plants to analyze
Indirect activities and recommend improvements. This was part of the
identification phase which lasted 8 weeks. I personally worked in 3
different plants.
. Performed a 4 day budget study to determine the cause of losses in the
service portion of the headlight business at the Visteon Sandusky
operation - located a $200,000 error and $500,000 in misallocated
burden.
. Directed IE team at 2 other locations studying truck drivers and
skilled trades.
. For more info see website - productivityteam.com.
. By the time the second phase began several months later in January I
had already accepted a position back at Delphi through ACRO Corp.
Early Retirement & More Education - Back to School
1/04 - 10/05
. Accepted an early retirement offer
. Decided to go back to school and attended classes full time at Mott
Community College (4.0 GPA) and Eastern Michigan University (3.97GPA).
. Attended evening classes through Dec 06 while working at Delphi for
Acro.
AC Spark Plug/Delphi -
Sr. Cost Estimator 8/99 -
12/03 This job typically was filled with experienced Industrial
Engineers
. Provided Material, Labor, and Investment costs, to Finance & Marketing
for Sales in response to Customer Requests, performed piece by piece
cost analysis and special studies.
. Worked with Product Engineers to understand and fine tune designs,
Process Engineering to understand and fine tune process plans, tooling
and investment costs and assembly sequencing, Industrial Engineers to
understand flow and fine tune labor requirements, Purchasing for costs
and timing of purchased components, Finance to develop and populate
cost/profit spreadsheets, and Marketing to assist in presentation
development, timing and volume data.
. Developed EXCEL piece cost spreadsheets with detailed labor and
material breakdown by component and volume levels. Investment of
capital, tooling and expense was broken down incrementally by volume.
Each component also had spreadsheet detail to build the cost. The
entire package was then internally benchmarked and analyzed with
Purchasing and the Product Team.
. Provided input, support and documentation for executive level review
boards
. Tracked monthly cost summaries, evaluated and tracked ECO's -
Engineering Change Orders
. Developed burden studies when appropriate.
. Participated on Cost Estimation Process Improvement Team - 20%
improvement in throughput time.
. Performed Circuit board component cost/supplier study - $400,000
savings. Served on Suggestion Committee
. Product Lines - air cleaners, air meters, oxygen sensors & cruise
control
. Processes I have developed costing include - electronic components,
castings, plastic injection molding, blow molding, stampings,
forgings, machined components, screw machines, cold heading, robotic
assembly, manual assembly, Degaussing, Magneform, Rubber Diaphragm
Curing, Electro-coat Dip Paint Systems, Powder Paint Systems, Infra-
red Curing, Plating, Washing, Ceramics, Welding, Wire Benders, Tube
Bending, automatic screw machines, Heat Treating, Degaussing,
Magneform, Rubber Diaphragm Curing, laser trimming, powdered metal
forming and machining, special handling, shipment and storage of
Platinum.
AC Spark Plug/Delphi
Manager/Floorspace Planner - Industrial Engineering -
6/88 - 8/99
. Supervised and Trained 7 Industrial & Plant Engineers and designers
. Conducted over 20 Theory of Constraints Workshops, Co-Facilitated
w/UAW dozens of Lean Manufacturing Workshops in direct, indirect and
maintenance areas, Led VA/VE workshops with managers, operators,
product engineer & purchasing in detailed, part by part cost analysis
- material, labor, investment, Led Lean Implementation, Implemented
cell manufacturing
. Led 2 major (many minor ones) material flow studies for plant
reorganization, implemented supermarket concept and cart system
delivery
. Yearly model change planning and development of material handling and
dock plans, warehousing layouts and planning, buffer sizes, dunnage
systems, supermarket planning, delivery routes and headcount.
. Yearly project budgeting, planning, scheduling and implementation of
major equipment and workplace alterations/installations.
. Maintained labor routings, Oversight and participation in time
studies, downtime studies and work sampling.
. Continued Floor Space Planning Responsibilities, constructed 40,000 of
office environment for Air Meter assembly, transformed sheet metal
facilities into plastic molding facility, Removed over 80 sheet metal
presses and installed twelve (12) 700 ton and ten (10) 1000 ton
injection -molding machines with overhead feed systems for three
different plastic code materials.
. Developed yearly headcount with management for manufacturing,
indirect, maintenance, and tool rooms.
. Assisted site conversion from zone to central and back to zone/plant
combo maintenance over 10 year period (now on MANIS), janitor manpower
plans, Served on Suggestion Committee Olimpic System Indirect Material
Implementation Team..
. Product Lines - air cleaners, air meters, oxygen sensors
. Various visits to suppliers, machine builders, and car/truck assembly
plants
AC Spark Plug/Delphi
Manufacturing Planning Administrator
3/83 - 6/88
. Responsible for 450,000 sq ft of floorspace planning, coordinating and
implementing Plant Layouts.
. Directed layout designer. Oversight and coordination of all layouts
with the IE's.
. Yearly Model Change floorspace planning, layout & construction
coordination. Consolidation & Entire Product Line relocation for 4 new
Product Lines.
. Planned the 3 year 200,000 sq ft transformation of a sheet metal air
cleaner transition to plastic design and followed through to
implementation.
. Planned ramp up of air meter production into the same plant.
. Planned & implemented automated material handling for Oil Filter
conveyance, accumulators and Powder Paint Systems
. Continued to be a part of Value Analysis/Value Engineering Team -
detailed part by part cost analysis - material, labor, investment
AC Spark Plug/Delphi
Industrial Engineer
6/77 - 3/83
. Area Engineering responsibilities - Time Studies, Work Sampling,
Downtime Studies, Assembly Line Development in the Methods Laboratory,
Value Analysis/Value Engineering Team - detailed part by part cost
analysis - material, labor, investment, Part of 3 person Team that co-
developed new IE Training Plan, Designed & simulated in Methods
Laboratory 1982 F-Car instrument Cluster Lines including multiple
balances w/quick change capability - 2 lines Firebird - 2 balances &
Camaro - 3 balances.
. Co-developed Training Plan for new IE's, Served on Suggestion
Committee, Start-up Liaison for Arlington Car Assembly plant
AC Spark Plug/Delphi Production Supervisor - 1st and 2nd shifts
1/74 - 6/77
. Supervised Service Packaging, various Instrument Cluster lines & Misc.
Speedometer & Tachometer Line during that time - each with 20+
operators per line, Supervised and helped design first quick change
instrument cluster assembly line at AC.
Pontiac Motor Division - General Motors
CO-OP Student - Purdue University & Pontiac Motor Division
6/69 - 12/73
. Engine plant - machining, fab & assembly & Car Assembly - B, G & C
body styles
. Sr. Project - Complete Training Responsibility for 750 engine Plant
employees for the 1973 Model Change - conducted 1 week train-the-
trainer classes, scheduled & coordinated departmental training by the
trainers
Two Relevant Major Projects
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. During the GM truck platform redesign of the 90's my team needed to
develop an assembly and delivery system for a very large plastic air
cleaner with only 24 assemblies per large shipping container; a wire
basket (45x48x52). This created a material handling challenge due to
the 5000 pcs per day requirement. In our lean analysis we determined
that we really needed to build a new 2 dock shipping facility adjacent
to the molding / assembly cells to expedite shipment and minimize
material movement and inventory. My team also recommended increasing
the number of ship windows to allow smaller in house finished goods
inventory. This was a hard sell for us because we rarely were able to
change our "monuments". It was a very easy and logical sell once we
worked through the emotion and reviewed the lean advantages of flow
improvements, inventory reduction and truck driver savings. The most
effective Lean tool used in the education process was a simple
spaghetti chart. Once the participants saw the overall product flow of
an improved layout, the enthusiasm built immediately. The headcount
and floor space savings exceeded expectations.
. During the recent Delphi outsourcing and downsizing in 2008 we needed
to consolidate and re-balance our Modular gas tank sending unit and
fuel pump assembly systems. We had 6 months to develop a plan and
relocate over 150,000 sq ft of stock, fabrication and assembly. I held
a key role in the team that crafted lean process improvements and
relocation possibilities of the assembly and stock rooms using flow
analysis. My specific individual role in our relocation team was to
develop block layout alternatives showing flow alternatives of the
assembly, stock room and fabrication areas into a different building
about a half mile away, the detailed layouts of the assembly and stock
room areas and the development of a new assembly line for a redesigned
module and the re-balancing of the current assembly lines to new
volume levels. I also assisted in the development and implementation
of the new kitting process, component delivery system and shipping
tugger system. We had weekly reviews with the site manager and
developed an acceptable plan using lean techniques. We realized a
significant floor space and headcount reduction. During the re-balance
phase of the project, I developed and led small teams of operators to
help develop the new concepts. They were trained in the necessary lean
concepts as appropriate and were instrumental in the new balance
development and workplace improvement. We completed the project on
time with very significant floor space and headcount reductions and
were in the changeover reduction mode when I left in October of 2008.
Favorite Pastimes:
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. Family activities, church activities, basketball & other sports,
building and 4 wheeling jeeps w/sons, bicycling
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