Christopher S. Sternad

**** ******** ****

Brecksville, OH 44141

H 440-***-****

C 330-***-****

abmcwy@r.postjobfree.com

CAREER SUMMARY

High-performing Project-Management Engineer with expertise in directing highly complex projects

that build/optimize organizational processes, measurement systems, and infrastructure to maximize

business results in manufacturing and service organizations worldwide. Skilled strategist who

transforms strategic plans into workable solutions. Lean manufacturing expert with proven track

record of structuring and implementing projects that yield measurable results, including reduced

tactical-planning cycle time, cost reductions gained from improved system/process performance,

productivity gains through multiple change and improvement initiatives, reduced product-development

time, and revenue growth. Keenly focused on customer requirements and service levels which directly

contribute to bottom line results. Specific expertise in the following:

• •

Project Management Excellent Communication Skills

• •

Design, Layouts, SOPs Superior Customer Relations and Service

• •

Troubleshooting / Problem Solving Process Design / Redesign

• •

Lean Mfg., Takt Time, Kaizen, 5S QS / ISO 9000, ASTM

• •

Total Quality Management Solidworks

• •

Productivity and Efficiency Improvement AutoCAD

• • MS Office

Cross-Functional Project Team Leadership

PROFESSIONAL EXPERIENCE

US Cotton, LLC. (Subsidiary of Parkdale Mills), Cleveland, OH 2007 - 2009

A manufacturer of cotton products.

Manufacturing Engineer

Planned, supervised, and designed layout of $1.5 M equipment installation and upgrade

project. Coordinated riggers, electrical, fire and HVAC contractors.

• Improved production efficiency from 73% to 105% in one year by redesigning the floor

configuration and process.

• Doubled output capacity of card room and created flexibility to run multiple product lines at one

time.

• Identified and corrected problems in plant involving parts, process / operations, and machinery,

saving 22 production days per year.

• Worked on safety issues plant wide. Created a safety guard that was implemented in all 3 plants.

• Designed 4 different stripper plates with parts made for a cost savings of $12,680.

• Rebuilt inline sealer equipment for a cost savings of $70,000.

American Weather Seal (subsidiary of Monarch Holdings), Orrville, OH

2007

A manufacturer of vinyl windows.

Process Engineer

Worked on new products engineering for glass doors, existing products, production issues, and

customer issues.

Christopher S. Sternad Page 2

• Implemented Lean manufacturing throughout the facility.

• Wrote Standard Operating Procedures (SOPs) for each workstation.

American Weather Seal (continued)

• Executed projects to improve productivity from 100 to 300 windows within 6 months.

• Improved line layouts and process flow using 5S methods and one-piece flow.

Fypon, LTD. (subsidiary of Fortune Brands), Archbold, OH 2004 - 2007

A leading manufacturer of Polyurethane millwork.

Process/Research & Development Engineer

Traveled to China to research new equipment and worked on production issues.

• Improved Rapid Injection Machines (RIM) molds by working on high tech equipment to make them

more functional.

• Ensured process improvements, efficiency, plant layouts, and scrap reduction activities.

• Designed a spraying system with a cost savings of $40,000.

• Designed 50, 60, and 80-ton screw presses to improve line efficiency and cost savings.

• Lean Core Team member/Facilitator of the Quality Lean Team / EHS Champion Leader.

Diebold, Inc. (Contract Position), Hebron, OH 2004

A manufacturer of ATM machines, safes, and under counter cabinets.

Process Engineer

Provided engineering support to powder coatings, sheet metal fabrications, press, and assembly

lines.

• Targeted problems in production and implemented Lean Manufacturing principles.

• Improved line layout and process flow for under counter cabinets.

• Coordinated and managed the responsibilities of Plant Manager in his absence.

Great Lakes Window (subsidiary of Nortek Corporation), Toledo, OH 2003

A major window manufacturer producing customized windows.

Process Engineer

Led 8D problem solving team for a new screen roller project.

• Managed run off and installation of new equipment, replacing 2.5 operators.

• Performed Poka-Yoke and trouble shooting on production fixtures and equipment.

• Conducted time studies to determine Takt Time and process capability studies.

• Designed fixtures and operated small fabrication machinery (punches, router, drills, milling

machine.)

Poly Hi Solidur, Inc. (subsidiary of Menasha Corporation), Fort Wayne, IN 2002 - 2003

World’s largest UHMW extrusion facility manufacturing rods, boards, tubes and profiles for the food,

agriculture, wastewater, automotive, and packaging industries.

Process Engineer (Extrusion)

Responsible for the UHMW extrusion process.

• Received Creative Thinking Award for proposal of quick setup and tear down on setting dies in

extruder, permanently attaching thermocouples to extruders to reduce scrap; plan was

implemented. Developed and optimized run parameters for new and existing dies.

• Created new resin formulation replacing old resin saving $40,000 per year.

• Reduced scrap from 6% to 4% by working with operators on startup and process procedures.

• Participated as member of QS/ISO 9000 Core Team for preventative maintenance program and

operator training.

Christopher S. Sternad Page 3

• Conducted raw material evaluations and studies.

Jideco of Bardstown, Inc. (Japanese owned company), Bardstown, KY 1999 - 2002

A 500-employee facility producing power window motors, blower motors, ABS motors, and cruise

controls for the automotive industry; Tier 1, Tier 2 automotive manufacturer.

Process/Production Engineer

Managed production lines of automatic braking systems motor / armature, motorized cruise controls,

and large actuator.

• Reduced ABS scrap materials from 12% to 3% over 3-month period. Reduced motor line noise

scrap from 2.65% to 0.30% over 5-month period. Reduced air leak failures by 75% providing cost

savings of $42,547. And reduced ABS scrap due to bad commutator bar producing a cost savings

of $6,959 / month.

• Saved $112,000 on ABS rework motors due to bad connectors on holderbase.

• Managed start-up of new multimillion-dollar power window armature line involving floor layout,

equipment specifications, and purchasing.

• Implemented Lean Manufacturing principles of JIT, Takt Time, Kaizen, 8D, One Piece Flow, Poka-

Yoke, Waste, and 5S.

• Participated on a cross-functional team consisting of Quality Engineer, Quality Technician, Group

Leader, and Plant Manager.

Highland Group Industries, Solon, OH 1997 - 1999

Private manufacturer of floor mats and cargo trays for major automotive clients; Tier 1, Tier 2

automotive manufacturer.

Project Engineer

Designed, prototyped, and developed new products such as truck tie-downs, ramps, rubber floor

mats, and anchor bolts using plastic, metal and rubber materials.

• Maintained documentation of PPAPs and APQPs.

EDUCATION

Bachelor of Science in Mechanical Engineering Technology

Courses: Calculus, Thermodynamics

Cleveland State University, Cleveland, OH

ADDITIONAL TRAINING / CERTIFICATIONS

HVAC Certification

PLC training

DFT Principles/Training

Visionary Leadership Course

Lean Manufacturing Training

Joachim Knuf, University of Kentucky

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