Engineer Manufacturing

Terry Battaglia

* ******* ******, ****** *****, NY 13148

315-***-**** ********@*********.**.***

Profile: Industrial/Manufacturing/Quality Engineer with over 32 years of

experience at Fortune 500 and 100 companies (BSIE degree). Environments

have included aircraft manufacturing, federal airport security,

manufacturers of RF and digital electronics, biotechnology, electro-

mechanical products, FDA medical devices and food processing. Ability to

evaluate both low-volume high-mix and high-volume production. Excellent

working knowledge of computer-aided planning and manufacturing systems.

Specialized training in lean/6-sigma, plant layout, work measurement,

methods engineering, validations, process engineering, and project

management.

Technical Skills and Expertise:

* Lean Manufacturing * Six Sigma * AutoCAD layouts * Project Management

* New Product introductions

* Work Measurement * Methods Engineering * Cost Estimating * Capacity

Determination * Ergonomics

* Statistical Process Control * Process Capability * Design Of Experiments

* FDA Validations

* Supervision of engineers and technicians

Key Career Accomplishments:

. Implemented manufacturing plans for military unmanned helicopters

. Developed security layouts for airports across the nation

. Established airport screener staffing levels based on flight schedules

. Successful track record introducing 48 new products and $1,373,000 in

cost reductions

. Transferred 40,000 sf of clean room ops from San Diego to Tijuana

saving $1.5 million/yr

. Generated work sampling studies recommending decentralized maintenance

saving $150,000 per year

. Developed capacity planning models for calculating staffing

requirements and machine loading

. Implemented Lean/6Sigma and Kanban systems reducing WIP inventories

48% saving $350,000/yr

Professional Experience:

sCHWEIZER AIRCRAFT CORP. (SIKORSKY), Horseheads, NY 1/2008-9/2008

Fixed-wing Aircraft, Manned & Unmanned Helicopters

Manufacturing Engineer (contract)

Planned, designed, and implemented manufacturing planning for manned &

unmanned helicopters

. Scrubbed helicopter Operation Sheets for accuracy in Solumina

. Created Operation Flow Diagram (precedence chart) for manufacturing

flexibility and planning

. Reduced waste in method instructions by eliminating material cross

references

. Converted from 3-station build to 5-station build to meet new Takt time

. Combined operations to eliminate redundant inspections

. Handled Discrepancy Reports & rework/repair instructions

. Verified MIL Specs for fasteners and provided reference material for

torques

. Value Stream Mapping, ECOs, Routings, and BOMs (SAP conversion)

. Capacity modeling including learning curves

. Plant layouts for strategic planning

TRANSPORTATION SECURITY ADMINISTRATION, Syracuse, NY 9/2002-10/2007

Federal Airport Security

Industrial Engineer

Designed and implemented AutoCAD layouts for passenger and baggage

screening at dozens of US airports

. Established TSA CAD Standards and equipment block library including block

attribute database

. Trained 25 other Industrial Engineers in the efficient use of AutoCAD for

layouts

. Assisted numerous architects, engineers, consultants, and construction

contractors

. Determined airport capacity requirements and screener staffing levels

(full and part time) to minimize passenger wait times and reduce federal

expenditures

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Professional Experience (cont.):

. Helped to develop models and used discrete event simulation program and

applied queuing theory

. Planned and implemented new technology equipment such as X-ray machines,

metal detectors, Explosives Detection Systems, conveyors, cameras, and IT

equipment for data collection

. Assisted in the design and construction of new airport terminals (OGS,

MSS, PLB/PBG, IND)

. Planned the complete relocation of airport security operations (UCA/RME,

ROC, MDW)

. Developed office layouts for federal support personnel (SYR, ART, ROC)

. Federal security clearance, Sensitive Security Information (Secret)

Philips Broadband Networks, Manlius, NY 6/1995-11/2001

RF electronics manufacturer for cable TV and telecommunications; 1,000+

employees

Manufacturing Engineer

Planned, designed and implemented layout changes for 1-piece flow and

efficiency. Championed lean/6-sigma process (Kaizen continuous

improvement). Managed Electrostatic Discharge (ESD) damage prevention

program.

. Designed and implemented Kanban card systems and Work In Process (WIP)

tags to reduce waste and prevent errors. Cards controlled the flow of

material by "pulling" demand and assuring First In First Out (FIFO).

. Developed and lead teams for Fishbone Diagrams (Cause & Effect) and Value

Stream Mapping

. Mentored 6-Sigma trainees for Process Capability studies (Cpk) and Design

Of Experiments (DOE)

. Developed and maintained layout drawings in AutoCAD for 200,000 sq.ft. of

manufacturing and office space to create database attributes (2,000+

pieces of equipment) used by engineering, facilities and property

accounting

. Justified, planned and implemented $80,000 automated material handling

(conveyor) system

. Level-loaded work centers based on Takt times

. Implemented computerized work measurement system to cut labor standards

maintenance costs by 50%.

. Wrote and implemented computerized work measurement system for assembly

line balancing to enable single-piece flow (COMSOAL method applied to

Precedence Diagram for new products)

. Supervised 3 engineers (Industrial, Packaging, and Methods)

Hybritech Inc. (Eli Lilly and Co.), San Diego, CA 5/1990-6/1994

Biotechnology firm for medical diagnostic test kits; 1,200 employees

Quality Engineer

Determined capacity plan for people and processes to meet $150 million

sales in biotechnology. Participated and led work improvement teams,

performed cost reduction analysis and efficiency improvements.

. Justified and installed 42 capital investments totaling $1.3 million

. Maintained AutoCAD drawings for 7 buildings (270,000 sq.ft.), including

equipment, material flows and air filtration systems

. Generated construction proposals for complex layouts for conversion to

work cells

. Led Quality Teams for continuous improvement (Leam/6-sigma) for

biotechnology processes.

. Wrote extensive FDA software validation abiding to established protocols

to ensure configuration and equipment reliability. Installation

Qualification (IQ), Operational Qualification (OQ), and Performance

Qualification (PQ). Saved $420,000 per year in pre-printed vial labels.

Systech Computer Corp., San Diego, CA 8/1988-5/1990

Digital electronics manufacturer for computer systems; 200 employees

Manufacturing Engineer

Reduced and simplified product flow. Installed and managed Electrostatic

Discharge (ESD) damage prevention program.

. Justified, planned, designed and implemented 8,000 sq. ft. relayout of

all PC board manufacturing operations that saved $300,000 in Work In

Process (WIP) inventories

. Implemented first electro-mechanical assembly line, converted from direct

bench work. Bought and installed equipment, balanced flow, produced

documentation and trained 12-15 operators

. Introduced 3 new products from beta builds to full production with fool

proof design for manufacturing

. Developed and implemented barcoded weigh-counting system for incoming

parts, eliminating the inefficient process of manual operator counting

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Professional Experience (cont.):

IMED Corp. (Fisher Scientific), San Diego, CA 3/1986-8/1988

Plastic injection molding and assembly of medical devices for infusion

systems; 800 employees

Quality Engineer

Planned new building layout and line layouts for transfer to Mexico,

ordered tools/equipment, handled customs permits, coordinated shipments,

line setup, training and post-production support.

. Consolidated and transferred operations between remaining buildings that

saved $63,000 annually

. Developed Elemental Standard Time Data and operation procedures

. Introduced 18 new products, such as IV tubing, from design to production.

Assumed role in planning and inputting Bills Of Material, routings,

operation process charts, and configurations. Saved $50,000 per year by

performing work previously assigned to Methods Engineering.

Prior Experience:

Fisher-Price (Quaker Oats), San Diego, CA 9/1981-3/1986

Manufacturing Engineer - Member of U.S. site team to support Mexican

electronics plant of 400 employees. Maintained Bills Of Material, routings

and configurations for Engineering Change Orders (ECOs). Developed

computer program to automatically balance assembly lines.

Chicken-of-the-Sea (Ralston Purina), San Diego, CA 5/1978-9/1981

Statistical Process Control Coordinator - Supervised 7 technicians.

Analyzed processes and bottlenecks; improved productivity and reduced costs

in 100K cans per day facility, employing 1,000. Studied dented can problem

and implemented solution with FDA-approved material handling modifications.

Saved $60,000 annually.

Armstrong, Braintree, MA 7/1977-1/1978

Industrial Engineer - Monitored material specifications and recipe changes;

maintained wage incentive standards in a unionized plant employing 500.

Worked on waste cost reductions and delays.

Education / Certifications:

BSIE, Industrial Engineering, Rensselaer Polytechnic Institute (RPI), Troy,

NY. Minor in Psychology.

Certified in Methods Time Measurement (MTM) I & II pre-determined work

measurement systems.

Certified in Maynard Operation Sequence Technique (MOST) pre-determined

work measurement system.

Certified in Industrial Hygiene Monitoring (OSHA-related for airborne

particulates and noise levels).

Certified in Configuration Management II (BOMs, routings, ECOs).

Certified in Lean/Six Sigma continuous improvement (Black Belt).

Affiliations:

Senior Member, Institute of Industrial Engineers (IIE). Active Member in

Syracuse Chapter.

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