Engineer Manufacturing

ROBERT F. PUCHALSKI C) 248-***-****

Lake Orion, MI 48362 abm38v@r.postjobfree.com

SENIOR ENGINEER - Advanced Manufacturing, Product Engineer and Tooling

Specialist

New Product Development / Launch; Supplier Development;

Molding with Tool and Die; Electro-Mechanical and Electronics Components

A cross functional engineering professional with a consistent record of

successful accomplishments including management of programs combining the

ownership of key leadership roles while also a strong team member.

Certified journeyman in Tool and Die, Stamping and Injection molding

operations which includes final assembly and automation related processes.

Extensive International experiences have included Asia, Mexico, and Europe

in both union and non union environments. Represents manufacturing

engineering at Fortune 500 companies, including GE, Whirlpool, Maytag,

Ford, GM, Chrysler, BMW, Harley Davidson and Sea Ray.

Core Competencies

. Program Management

. Supplier Management/Development

. Catalyst of financial approved funding

. Quality Improvement by Global Design/Manufacturing Best Practices

. Technical supervision to plant engineering

. Sales cost estimations on new product designs

. Generate cost reductions w/ new and current products

. Future strategy development and operation

. Product design benchmarking and evaluation

PROFESSIONAL EXPERIENCE

DELPHI AUTOMOTIVE, Auburn Hills, MI

2000 - 2009

Senior Tooling Engineer - Advanced Manufacturing - New Product and

New Business Development

Responsible for leadership of all advanced engineering development relating

to component tooling and end product design for manufacturability. This

included manufacturing strategy and implementation of complex new products

including electromechanical products, automotive interior and exterior

switches, sensors, electronic modules and integrated assemblies. Lead role

in industry first steering controls for the marine recreational market

which required a 6 month "award to launch" customer requirement that was

successfully completed. Administered supplier initiatives for related

products utilizing ISO, TS, PPAP, and APQP industry standards.

Key Accomplishments

. Coordinated new product fabrication, process assembly, equipment, and

tooling estimation for all new concept and business development

activity. Manufacturing Engineering focal point with all customers and

suppliers from initial concept through product launch as well as

continuous improvement of programs in production.

. Created and implemented process and design for product introduction of

new electromechanical products (i.e. column stalk switch systems and

window lift switch assemblies for multiple OEM's and platforms. Ensure

financial funding, procurement and supervised program timing for

multiple successful program launches.

. Served as program manager / tooling liaison with Asian fabrication and

injection molding suppliers.

Results: $300,000 savings on a supplier resourcing of a $1.5 million

program for a major automotive OEM.

. New material research and change to automotive integrated overhead

control module for major OEM. Key program with new N.A. customer that

had new product and program requirements.

Results: Injection molded material originally slated for $2.50 per #

vs. recommended re designed material @ $1.20 per # equaled $450K

program savings.

EATON AUTOMOTIVE VSED MECHATRONICS, Downers Grove, IL 1998 - 2000

Senior Engineer - Divisional Manufacturing New Product Development

and Current Products

Designed products for vehicle systems, switches and electronics for many

OEM customers and markets. Provided specialized expertise support to the

global manufacturing and engineering organization by effectively

communicating knowledge of the industries leading technological

developments. Ensured design integrity by leading the use of manufacturing

and design best practices while monitoring early stages of product

development in R&D.

Key Accomplishment

. Implemented continuous flow, cycle time reductions, and lean

manufacturing techniques in border facilities. Results: Improved

process / product designs for high volume products; reduced specific

costs by $.05 / piece on $8 million worth of product assemblies

annually.

INVENSYS CONTROLS, Carol Stream, IL 1991 - 1998

Divisional headquarters for International manufacturer of valves,

regulators, timers and electronic components for major OEM's. Customers:

General Electric, Whirlpool, Maytag, and Electrolux

Engineer - Divisional Manufacturing I - Automation and Tooling

(component and assembly)

Managed performance measurables and impact of capital expenses annually.

Supervised and monitored numerous programs through completion and post

audit.

Key Accomplishments

. Developed concepts and process improvements for reduction in costs and

improvement of quality.

. Created reference standards for capital equipment procurement.

. Standardized recommended equipment and preferred vendors for

divisional plants. Laundry valve design and introduction.

Results: Implemented new generation appliance product in seven

months (on time) for a major OEM customer. Market share increased to

93%.

EATON CORPORATION, Automotive and Appliance Controls, Carol Stream, IL

Divisional Tooling Engineer II

1984 - 1990

Responsible for conceptual designs, formal design, piece part equipment

purchasing, in-house internal building and debugging of specialized high

speed proprietary equipment for individual facilities in automotive and

appliance related products. Ensured design integrity and internal in-house

machine building as directed by individual plant needs for cost incentives.

Key Accomplishments

. Developed new advanced process for products with the usage of machine

building techniques and standards with in-house capabilities.

. Reduced capital cost internally with the purpose to secure proprietary

in house building of specialty equipment.

Results: Concepted - designed - purchased advanced auto soldering

machine for an Appliance Automotive applications; reduced part costs

by $.15 / piece on an annual production requirement of four million

pieces. Internal savings of $ 600,000.

FELT PRODUCTS, Skokie, IL

(Federal Mogul Acquisition) Machine operator / Quality Inspector / Tool

room Asst. Supervisor / Class "A" Tool and Die

Molds / Machines / Fixtures / Specialty Machine Building / Head Internal

Apprenticeship Programs

EDUCATIONAL / TRAINING EXPERIENCE

Triton College, IL - BS prerequisites in Mechanical Engineering

Walsh College, Troy, MI

- Graduate Business Administration School, MBA, Take Charge Series

(Business and Leadership)

- PMI precertification in process; along with continuing education

courses (expectation 2nd Qtr 2010)

University of Milwaukee, WI

- Planning for Cellular Manufacturing

- Product Liability and Patents for Certification for Internal

Instruction

- ISO, QS & SPC Quality Certification & Training

- DFMA (Design for Manufacturing & Assembly)

- DFS

- Automation

Northwestern University, IL - Quality by Design

Triton College - Design for Robotics, Automation Design and Reliability

Government Tool and Die

- Div. of Labor Standards (5000 credited hours)

- Advanced Die / Mold Design (1000 credited hours)

Eaton VSED Divisional Instructor - DFMA (Design for Manufacturing &

Assembly)

Design for Manufacture and Assembly Certification, Boothroyd / Dewhurst

Simulation for Manufacturing, ProModel

Front-Line Management / Leadership, Zenger Miller

Plastic Part Design / Development and Purchasing, Society of Manufacturing

Engineers (SME)

Geometric Tolerancing and Geometric, Mueller & Associates

Eaton and Delphi

- Six Sigma Training

- Green / Black Belt Quality Certification & Training

- Capital Expenditures / Asset Training

- ASMC, APQP, PPAP, Quality Supplier / Customer Training

Awarded 2 United States Patents - Gas Burner Switching Ignition Assembly

and Auto Industry Switch

Honored Membership - Corporation Patent / Individual Government Design

Patents

Senior Member - Society of Manufacturing Engineers

TECHNICAL ADDENDUM / CERTIFICATIONS

Manufacturing and Tooling Association, Tool and Die Institute (Government

Certified)

Certified Corporate Instructor - DFMA and DFM (Boothroyd / Dewhurst)

Purchasing / Procurement Certified Training

Financials on Capital Expenditures / Asset Training

AutoCAD

Pro E

DFMEA & PFMEA, Root Cause Analysis,

DFA, DFM, DOE, 5Y Analysis

V5 Catia Modeling

Mold Flow

Expertise in Quality Processes & Manufacturing Building Block Technologies

Quality Supplier Audits with Quality Improvements

Molding (straight, insert, decorative, multi-shot)

Stampings (straight, plated, precious metals)

Paint and Laser, Pad Printing, In Mold Laminations

Automation with Validation, Audit and EOL testing equipment

TALCS Requirements (Touch, Appearance, Lighting, Color and Sound)

Systems and System Integration with Tiers and OEM's

Self Leadership Expertise / Globally

Automotive customers: Ford, Nissan, Chrysler, GM, Daimler, BMW, Toyota,

Hyundai, Volvo, SAAB and VW

Non-automotive customers: Harley Davidson, Sea Ray, International,

Freightliner, Kohler, Whirlpool, After Market Products (Delphi), Consumer

Products (Delphi), Medical (Delphi) Extensive OEM and corporate internal

experience in Europe (Germany) and Asia

Program Manager / Technical Leadership

Expertise with multiple OEM Product Development Processes and Validation,

Process Flow.

Expertise with multiple Tier 1 Product Development Processes (i.e. Delphi

Product Development Launch Process - PDLP and the Eaton Product Development

Process - PDP)

Strong Proven Reputation in Key Interpersonal Leadership Skills

Team building, mentor, reputation of building a culture of trust and

respect, leading by example, self motivated, decision maker, "consistently

exceeds expectations" and "outstanding" ratings in personal business plan

reviews, global customer and supplier expertise, commitment with an

interest to succeed.

INTERESTS / HOBBIES

Recreational Outdoors interest in Boating, Fishing, Camping, Master Angler

Award - Fresh Water Lake Mich.

ADDITIONAL RESUME ADDENDUM

Personal Product Launches & Actual Experiences in NA & Globally

Automotive & Related Electronics Appliance & Related Electronics

Engine Throttle Controls Laundry Backsplash Panels

Engine Cruise Controls Laundry Water Valves - Hot, Cold

Engine Cooling Thermal Mechanical -Thermistor

Thermostats Laundry Water Level Switches

Engine Vacuum Ported Actuators Laundry Pressure Switches

Engine Management Vacuum Ported Sensors Laundry Integrated Timers

Engine Management - Temperature Sensors Appliance Cook Timers - Micro Wave /

Engine Management - Knock Sensors Oven Electronics

Engine Management - Oxygen Sensors Appliance Hot / Cold Thermostats -

Exterior / Interior HVAC Actuators Laundry / Refrigeration

Temperature Sensors Hot Temperature Thermostats & Controls

Steering Column Modules with Angle Sensors Cold Thermostats

Gas Appliance & Electronics - Cooking /

Steering Column Pedal Adjust Laundry

Steering Wheel Controls - Auto/ Pleasure Gas Ignition Cooking Controls Valves

Craft Gas Range & Oven Valves

(Sea Ray) Gas Cooking Laundry Ignition - Glow Bar

Vehicle Interior Info tainment Roof / Seat and Electronic Cook Top Switches

Mod. Refrigeration Defroster Controls

Vehicle Info Displays with Cluster IP Ice Maker Water Control Valves

Integration Dish Washer Controls for IP Display

Integrated Center Console Controls - Industrial & Electronics

Switch Bank Home Elect. Power Management (Cutler

Battery Temp Sensors Hammer)

Battery Power Management Controls Farm Load Cell - Farm Equipment Weight

Interior and Integrated Switch Bank Control Management

Controls Industrial Hydraulic Hose Connectors &

Column Stalk Controls Fluid Sensors

Interior Heated Seat Switch Modules Load Cell - Weight Control Management

Exterior Mirror Actuators / Sensors (Lear Jet)

Exterior Door Lock Handles Roadway Bridge Spans for Vibration and

Power Train Hydraulic Hose / Fittings Thermal Expansion - Polymer Molding

Power Train - Transmission Gear Processing

Vehicle Brake Products

Interior Seat Restraint / Harness

Assemblies

Window / Door Lift and Lock Controls

Interior Door Panel Parts

K

Keywords:

Manufacturing, QA, Quality engineer, quality improvements, process

engineer, molding, stamping, tool and die, procurement, liaison,

management,

supervisor, technical, professional, supplier quality assurance,

purchasing, director, product engineer, design, automotive, appliance,

fixture design, assembly, automation, equipment, facilitator, director,

Asia, tooling, DFA,DFMA, government, product design, modeling, cad,

tolerance, electrical, electronic, CNC, programmable, warranty, commercial,

cost reduction, strategic planning, benchmarking, advanced technologies,

estimation, validation criteria, lean manufacturing, lean engineering, oral

communications, skills, authority, negotiations, brainstorming,

motivation, Lean, KanBan, Kaizen, Six Sigma, Black or Green Belt, Lean

Manufacturing, Continuous Improvement, Engineer, NPI, Product Launch, SMT,

PCB, Solder, Muda, Poke Yoke, Error Proof, DOE, Design of Experiments,

TS16949, QS9000, FEMA, PPAP, CMM, CPVC, PVC, CAD, ProE, Pro Engineer,

robots, mechanical, hydraulic, systems, electromechanical.

Contact this candidate