Engineer Manufacturing
Resume:
STANLEY J. RYS
Northampton, Massachusetts 01062
Home: 413-***-****
Cell: 413-***-****
E-mail: *********@**.***
SUMMARY
Experienced Manufacturing/Process Engineer with proven track record over 15
year period. Certified Six Sigma Black Belt. Extensive Lean Manufacturing
training and application. Has managed subordinate engineers as well as
hourly personnel in high-volume manufacturing environments. Ability to
manage several major projects simultaneously. Tireless effort in
completing projects in a timely manner within budgetary constraints. Has
experience and knowledge of Facilities, Environmental Health & Safety
regulations, Quality, subassembly operations, finishing, and final
assembly. Utilizes statistical techniques to monitor processes. Was
Certified Lead Auditor for ISO 9000:1994. Utilizes quality standards set
by Automotive Industry Action Group (AIAG). Eagerly accepts challenges and
is quick to learn. Strongly promotes team environment and cross-functional
communication. Ability to integrate product design with manufacturing by
utilizing education and experience.
EXPERIENCE
Troy Industries, West Springfield, MA 2009 - Present
Manufacturing/ Quality Engineer
Responsible for implementing Quality System, reducing costs, improving
manufacturing techniques, and implementing Lean Manufacturing.
. Designed Go/No-Go gauges to reduce inspection time for Ruger products
by 50%.
. Created Work graphic Work Instructions for assembly, packing, and
inspection operations.
. Reduced cost of outsourced laser engraving service. Annual savings
$10,000.
. Created assembly cells. Improved productivity 40%.
HCP Packaging USA, Inc., Hinsdale, NH 2008 - 2009
Continuous Improvement Engineer
Responsible for implementing Lean Manufacturing.
. Liaison to New Hampshire MEP (Manufacturing Extension Program) for
Lean Manufacturing training under state grant.
. Trained over 60 associates, not covered by MEP grant, in Lean
Manufacturing techniques.
. Designed and implemented new Repacking process never previously
performed at plant. Helped implement bar coding procedure.
. Led Value Stream Mapping for Design-A-Lash product. Reduced product
travel by two miles. Reduced Inventory by $70,000.
. Led Kaizen for Injection Blow Mold setup reduction. Reduced setup
time by 40%.
. Conducted TPM Kaizen for capping machines. Reduced downtime by 50%.
. Black Belt project reduced torque failure by 60%. $65,000 annual
savings in scrap.
. Created written procedures. Supervised document control.
. Redesigned Move Tickets for transporting product. Reduced operator
paperwork by 50%.
Smith & Wesson, Springfield, Massachusetts 2004 - 2007
Lean/Six Sigma Black Belt
Implemented Lean Manufacturing with Toyota Production System (TPS)
techniques throughout Pistol portion of business. Constructed "Visual
Factory." Spearheaded 5S Program. Utilized Black Belt training for
problem solving. Implemented Cellular Manufacturing. Created Standard
Work.
. Cell Coordinator for Pistol Range and Packing areas. Effectively
managed 16 associates.
o Eliminated auditing by incorporating process into packing
procedure.
o Created Standard Work.
o Improved delivery to Finished Goods by 15%.
. Conducted series of Kaizens throughout Pistol Business.
o Implemented Kanban system for barrels. Shipped product for
Melonite process by ground, instead of air, saving over $100K
annually.
o Eliminated inspection process at Packing area by incorporating
inspection into the packing process. Developed rust inhibitor
application to eliminate customer complaints of rusted products.
. Implemented Kanban system for slide and frame forgings. Reduced
inventory 32% freeing $70,000 cash.
. Designed and Implemented Barrel Finishing Cell. Reduced lead time by
two days and eliminated two operators. Improved productivity 80%.
. Initiated Scrap Reduction Program utilizing communication and Poke-
Yoke techniques. Reduced scrap 75% saving $108,000 annually.
. Green Belt project to eliminated late shipments of SW99's by
shortening throughput. Accomplished by implementation of Kanban
system at machining and decreasing lot size. Annual savings of
$70,000 and potential for $100,000 additional revenue.
General Cable Corp., South Hadley, Massachusetts 2003 - 2004
Process Engineer/Facilities Manager
Supported manufacturing with required specifications and documentation.
Drove process improvement projects. Certified Six Sigma and Lean Sigma
Black Belt. Lean Manufacturing Leadership training. Managed
Facilities/Maintenance Department. Was responsible for plant Environmental
Health & Safety. Maintained detailed project files, which included, but
was not limited to, process instructions, facility requirements with CAD
layouts, cost tracking, statistical analysis, Preventive Maintenance (PM)
programs, and gauging requirements.
. Managed six employees in the Maintenance Department and one Lab
Technician.
. Converted Kinrei bunching machine to accept smaller reels and increase
production. Annual savings: $63,000.
. Black Belt project to reduce variation on Navy power cable OD. Annual
savings in excess of $200,000.
. Lean Project to modify Northampton bunching machine to accept smaller
reels. Increased speed of production by 53% by eliminating outdated
equipment. Eliminated non-value added operation of rewinding. Annual
savings: $109,000.
. Developed and implemented Engineering Change Notice (ECN) system.
. Revised Work Instructions to include more graphic details. Added
Critical to Quality (CTQ) and Critical to Process (CTP) criteria.
Murray, Inc., Lawrenceburg, Tennessee 1997 - 2003
Process Engineering Leader (2000 - 2003)
Managed the Process Engineering Department. Was responsible for supporting
product development in a timely and cost-effective manner. Maintained
detailed project files which included, but was not limited to, process
instructions, job balancing, facility requirements with CAD layouts, cost
tracking, statistical analysis, process FMEA's, Preventive Maintenance (PM)
programs, fixture design, and gauging requirements. Requested and
maintained budgetary requirements.
. Managed three subordinate engineers before company downsizing.
. Designed and implemented entire manufacturing process for
Chipper/Shredder business purchased from competitor.
. Relocated Snow Blower manufacturing business from satellite plant and
increased production 100%.
. Relocated two assembly lines from satellite plant and set up as Flexible
Cells to run multiple products including Edgers, Cultivators, and String
Trimmers.
. Programmed CNC tube bender to produce handles for Snow Blowers, Go-Karts,
and Edgers.
. Implemented effective torque control program for critical snow blower
applications. Tracked program with SPC.
Advanced Process Engineer (1998 - 2000)
Responsible for investigating innovative technology to replace existing
processes. Relocated processes to and from satellite plants. Fulfilled
Facility Engineering requirements.
. Designed and implemented entire manufacturing process for new Mini-Bike
product line by modifying existing equipment.
. Designed and implemented intermittent conveyor system to apply decals to
bicycles.
. Reduced Small Lot Rider product cost by $64 per unit by replacing large
metal stampings with consolidated injection-molded plastic parts. Also
outsourced smaller parts at lower cost.
. Implemented transfer system to install riding mower cutter decks on
Stanley products.
Quality/Manufacturing Engineer (1997 - 1998)
Responsible for providing manufacturing support for Bicycle Business.
Major player in ISO 9000 certification. Spearheaded Continuous Improvement
program.
. Implemented team concept into business.
. Developed quality plan for bicycle fabrication.
. Designed and implemented gauging and calibration schedule for Bicycle
Business.
. Developed sample boards at Bicycle Final Assembly and Bicycle Fabrication
(Welding) to clarify product acceptability of weldments.
Smith & Wesson, Springfield, Massachusetts 1993 - 1997
Industrial/Facilities Engineer (1994 - 1997)
Responsible for converting plant from batch-type layout to cellular
manufacturing. Interfaced with utility companies for concessions and
project grants. Maintained all facility requirements including Energy
Management System.
. Reorganized plant from batch-type layout to cellular manufacturing in
less than one year while creating 20,000 square feet of available
manufacturing space.
. Obtained capital grant from Northeast Utilities to install energy-
efficient dust collection system for polishing revolvers.
. Obtained utility concession from Northeast Utilities by simulating plant
move to Oklahoma City resulting in $30,000 annual savings.
CAD Operator (1993 - 1994)
Was responsible for measuring and drawing entire plant on CAD system
including machinery, equipment, and utilities.
. Maintained plant layouts.
. Supported manufacturing.
EDUCATION & TRAINING
BS, Engineering Technology: Manufacturing Engineering Option, Middle
Tennessee State University, Murfreesboro, Tennessee (2001), 3.49 G.P.A.
AS, Mechanical Technology: CAD/CAM Option, Springfield Technical Community
College, Springfield, Massachusetts (1992), 3.99 G.P.A.
Industrial Engineering major, transfer student, Western New England
College, Springfield, Massachusetts
Certified Lean Six Sigma Black Belt
LE 102 Lean Manufacturing
Job Instruction Training (TWI: Training Within Industry)
ISO 9000:1994 Lead Auditor Course (Honors)
FMEA Fundamentals
Assembly Plant Layout
Gage Calibration
Compressed Air Systems Workshop
OSHA Compliance: The Two-Day Certification Workshop
Project Management
Wire Drawing Die Seminar and Workshop
Hazardous Waste Management Course
SPCC & Tank Integrity Testing
Hazardous Materials Course
Production Part Approval Process (PPAP)
Managing For Performance
COMPUTER SKILLS
Windows, Word, Excel, PowerPoint, MS Project, AutoCAD, CADKEY, Microstation
'95, Cincom MRP, HFA (AS/400) MRP, Macola MRP, Minitab
ASSOCIATIONS
Society of Manufacturing Engineers (SME), Associate Member
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