Engineer Process

Johnie W. Levell

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

Wichita Falls, TX 76310

Ph: 940-***-****

E-mail: ********@*****.***

OBJECTIVE:

A Lean Manufacturing Engineer position utilizing solid

manufacturing knowledge, project management skills, and

process improvement experience to produce superior quality

products with fewer defects in a customer-focused, team-

oriented environment.

EXPERIENCE:

05/2004 - 01/2010 Alcoa Howmet Castings, Wichita Falls, TX

PROCESS ENGINEER

. Responsible for process development, stability, and

integrity on many aircraft engine blades and vane segments

according to AS9100

. Acquired extensive knowledge of wax, shell, cast, and

post-cast processes in an equiax vacuum casting

environment

. Assisted product engineers with dimensional conformance

issues such as wall thickness and metal straightening

. Experienced in core floating techniques, core

stabilization, KOH leaching and core break problem

solving

. Performed wax injection trouble-shooting parameter

checks

. Determined optimal dip and drain angles, drain times,

and stucco sequencing

. Solved shell-splitting and alloy leakage issues

. Identified and solved scrap and rework issues such as

inclusions, porosity, core breaks, mechanical cracks,

hot tears, and MMR

. Designed wax gating and sprue systems for optimal

solidification and gate removal

. Responsible for scrap cost-avoidance of $462K in 2008

and over $500K in 2009, as well as enabling over $7.3M

in additional sales

. Clearly communicated written and verbal work

instructions

. Coordinated metallurgical process validations with

customers

. Maintained sound customer relations and communications

. Worked within a set timeframe on multiple projects

. Designed gating systems, fixtures, and layouts

. Highly skilled in data-based decision making and root-

cause problem solving

. Proficient in Microsoft applications, Minitab, and

AutoCAD

05/2003 - 05/2004 Alcoa Howmet Castings, Wichita Falls, TX

Engineering Co-op

. Worked through MyStaf as a temporary worker and was

hired by Alcoa immediately after graduation

. Assisted engineers in process development and

improvement

. Monitored production quality and expedited improvement

trials

. Reduced rework on a complex cored blade from 50% to 3%

06/2001 - 05/2003 M&M Manufacturing, Wichita Falls, TX

06/1998 - 10/2000 LAYOUT MAN

. Designed and constructed unique sheet-metal fabrications

to meet customer requests

. Specialized in custom HVAC fittings and roof flashings

. Skilled in sheet-metal forming, rolling, soldering,

locking, and spot-welding

Johnie W. Levell

4610 Sherry Lane

Wichita Falls, TX 76310

Ph: 940-***-****

E-mail: ********@*****.***

11/2000 - 06/2001 Larrance Steel Corp, Lawton, OK

LAYOUT MAN

. Oversaw design accuracy and fabrication of heavy steel

construction

. Ensured construction quality met blueprint specifications

. Supervised a crew of two helpers and a welder

EDUCATION:

Midwestern State University, Wichita Falls, TX

BACHELOR OF SCIENCE IN MANUFACTURING ENGINEERING TECHNOLOGY

Graduated: May 2004

GPA: 3.244

Villanova University, Villanova, PA

Six Sigma Green Belt Certification

Completion: Expected August 2010

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