Manager Injection Molding
Resume:
RONALD W. FIALKO
Maineville, Ohio 45039 Home:
abmcpg@r.postjobfree.com ` Cellular:
Education
BSME, Bradley University 12/80
MBA, Finance, Rockhurst College, 12/85
Skills
SMED FMEA GD&T Lean Manufacturing
Kaizen JIT 5S TPM
TQM Cellular Mfg. Project Management Construction
Facilities Injection Molding Compression Molding
Extrusion
Tooling Fixtures Design P&L
Assembly Capital Projects Processing International
Travel for Molds and Tools
PFMEA Materials Equipment Purchases Thermoset molding
APQP
Experience
KurzKasch -($24 million in sales for custom molded coils.) Miamisburg, OH
Position: Production Manager and Program Manager (Contract)
9/09- 3/10
Responsibilities: Responsible for a team of 6 area leaders and
processing and maintenance team of custom molded coils in thermo-set
and thermoplastics. I have launched new programs through the PPAP and
APQP systems. Lead the team in continuous improvement initiatives
focusing on initial stages of process improvements & reliability,
changeover and scrap reduction.
Key Accomplishments:
* Establishing a teamwork environment for employee goals and
objectives in 4 months.
* Efficiency Improvement from 41% to 85% in 6 months
* Reduction in scrap from 20% to 8% in 4 months.
* Launched and managed a cable assembly for Behr through PPAP on
time within Budget in 5 months.
* Launched two thermo-set molded coil assemblies for Ford Programs
through the APQP and PPAP system in 6 months.
* Launched thermo-set molded coil assemblies for an improvement
programs on Ford products through Six Sigma training, Kaizen,
and Kemper Trego studies and savings in 2 months.
*
Dorel - ($400 million in sales for baby products such as car seats,
boosters, etc.) Columbus, IN Position: Operation Manager
and Launch Manager 4/08- 9/09
Responsibilities: Responsible for a team of 12 salaried employees and
350 union employees in the Indiana plant for sales to customers such
as Target, Wal-Mart, Sears and K-Mart. Launch manager for new
products, new tooling and new materials. Lead the team in continuous
improvement initiatives focusing on initial stages of process
improvements & reliability, changeover and scrap reduction.
Led the team in selection, and processing for new materials for new
products.
Key Accomplishments:
* Establishing a new culture for teamwork, improving efficiency of
100 injection molding presses, and establishing a win/win for
this supplier of car seats, strollers and child items in 12
months.
* Efficiency Improvements from 85% to 99% in 10 months.
* Scrap reduction from 4% to 2% in 12 months.
* Launched and managed 15 new programs for new green materials in
Baby products in 10 months.
* Launched and managed two new car seats in 6 months that meet
federal requirements.
* Launched and managed 200 different color and material changes in
12 months.
Century Mold - ($17 million in Sales Automotive Supplier) Monroe, OHHH
Position: Plant Manager and Plant Program Manager
1/06 - 7/07
Responsibilities: Responsible for a team of 10 salaried and 130 non-
salaried employees in a startup company selling products to Visteon,
Behr, and Valeo. Lead the team for injection molding project
justification, building construction, equipment selection,
installation and start up. I was the Plant Launch Manager for new
programs.
Lead the team in continuous improvement initiatives focusing on
initial stages of process improvements & reliability, changeover and
scrap reduction.
Key Accomplishments:
* Established a team, in supporting 11 injection molding presses
in 6 months.
* Setup the plant for TS approval in 3 months.
* Complete new plant startup in 3 months.
* Launched and managed 25 programs for Behr through the PPAP
process in 12 months.
* Launched and managed 4 new programs for Ford and Visteon in 4
months..
* Launched and managed a molded radiator end tank assembly for GM
through the APQP process in 6 months.
* Launched and managed 120 Chinese parts for Valeo in supplying a
low cost alternative in 5 months.
* Launched and managed 10 two shot program parts for Valeo through
PPAP process in 6 months.
Valeo Climate Control - ($160 million in sales Automotive Supplier)
Hamilton, OH
Position: Business Unit Manager and Program Manager
3/99 - 11/05
Responsibilities: Responsible team of 12 salaried and 120 non-
salaried employees in a tier one supplier of HVAC systems for all the
automotive companies selling in North America. I was responsible for
launching parts and tooling for new existing and new programs. Also,
was responsible for injection molding project justification, building
expansion, equipment selection, installation and start up. Lead the
team for injection molding project justification, building
construction, equipment selection, installation and start up. Lead the
team in continuous improvement initiatives focusing on initial stages
of process improvements & reliability, changeover and scrap reduction.
Key Accomplishments
. Injection molding department startup in 6 months.
. The injection Molding Department increased the Gross Profit
Margin by 16 points in 9 months.
. Managed PAPP and validation of 12 different programs in 12
months.
. Developed an international mold standard that is still used
today in 6 months.
. Managed 130 new molds per year across the world.
. Managed a department scrap rate of 1 % in 5 months.
. Developed SMED on all molds in 6 months.
. Managed part designers for tooling, assembly and manufacture
capabilities for all programs in 15 months.
. Launched and managed 12 different automotive platforms programs
for Behr and Chrysler through the PPAP process in 8 months.
. Launched and managed two new automotive platforms for
Freightliner through the APQP process in 4 months.
. Launched and managed two new automotive platforms for Mazda
through the PPAP process in 6 months.
NuTone -($450 million in sales Building Products Supplier) Cincinnati, OH
Position: Product Manager- Program Manager - Ventilation
Division 3/97 - 3/99
Responsibilities: Managed design of building products from
concept through production in the building product manufacturer of
ventilation and electronic products marketed through multiple
channels. Established and monitored budgets, process refinement, head
count reduction, incorporating automation, and establishing product
requirements. I was the Program manager for plant launches and
production issues. Lead the team in the following products (Indoor Air
Quality Products, Exhaust Fans, and Accessories) in strategic planning
and market decisions.
Key Accomplishments
. Launched and managed 70 new products in three months to support
a new $10 million business in 9 months.
. Lead two major cost saving programs, which delivered savings of
10 and 15% per part in 4 months.
. Lead in the development of interchangeable fan/light
combinations, motor assemblies, and decorative lights to capture
market dominance in 6 months.
. Launched two new bath exhaust fans for Lowes per industries
standards in 12 months.
. Launched one new range hood exhaust fan per industries standards
in 10 months.
Plastic Molding Corporation- ($20 million in sales Automotive Supplier)
Cincinnati, OH
Position: Plant/Project Engineer
8/94 - 3/97
Responsibilities: Managed a team of 7 salaried employees and 120
employees that provides plastic parts and components to the automotive
industry. Lead all injection molding processes, validation, process
flow, and maintenance department. Also, responsible for project
launches in thermoplastic and thermo-set plastic parts and components,
tooling, quality issues, customer contacts, lowering scrap costs, and
new automation.
Key Accomplishments
. Increased the gross profit margin by 10% through the
restructuring of process in 15 months.
. Lower scrap cost from 30% to.4% by tooling improvements and
customer involvement in 12 months.
. Launched and managed two new spark tube products for Toyota
through the PPAP process in 6 months.
. Launched and managed 5 different programs for the Ford through
the PPAP process in lighting in 6 months.
. Launched 20 different thermo-set parts in injection molding in
20 months.
. Restructured and re-furbished the thermo-set fiberglass molding
area to improve quality, lowered scrap and improve efficiency by
15 points in 10 months.
Ethicon Endo-Surgery Inc. - ($1.0 billion Medical instruments company) Blue
Ash, Ohio
Position: Manufacturing/Project Engineer
7/91 - 7/93
Responsibilities: Led two cross-functional teams of 20 salaried
employees to design and develop medical instruments products from
initial conception through production. Accountable for validations,
design for manufacturing, quality acceptance and non-conformances.
Also, responsible for product improvements, packaging, surgeon input,
and product acceptance
Key Accomplishments
. Organized a process map to reduce line scrap from 40% to 2% in 4
months.
. Set-up SPC at outside injection molding suppliers to lower scrap
from 30% to 1% in 6 months.
. Maintain the budget and time line for both projects in 9 months.
. Launched and managed two new medical instruments through the 410
K process in 12 months.
Allied-Signal Corporation - Kansas City, Missouri
Position: Plastic Senior Engineer (Government contract company)
1/81 - 7/91
Responsibilities: Led laser-machining team in $133 million plastic
division makings non-nuclear components for nuclear weapons for the
reduction of scrap and rework as part of a government-contracted
company under the aerospace division, that has sales of $350 million.
Also, Led and implemented tooling and manufacturing process
improvements to reduce costs Increased efficiency and productivity of
precision metal and plastic components. Responsibility for process/
product of establishing and maintaining reliable injection molded and
thermo-set plastic products.
Key Accomplishments
. Directed the Plastic Department in reducing injection molded
scrap from 12% to 2% in 6 months
. Organized a laser team that saved $28 million in laser cutting
circuit boards in 5 months.
. Saved $280 million by avoiding a recall of an Electro-mechanical
device in the field in 11 months.
. Developed a machining system to reduced scrap of a $25,000
component from 50% to 0% in 14 months.
. Launched and managed 20 new parts per year through the
government requirements.
. Launched 10 new thermos-set fiberglass parts per year through
the government requirements.
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