Engineer Customer Service
Resume:
Montour Falls, NY
Phone 607-***-****
E-mail ********@******.***
Mark Wilhelm
Special Skills
AQPQ ( GM, Chrysler) PPAP, FMEA, Control Plans,
Process Mapping, 8D, 5S, Kaizen, Poke-Yoka, Lean
Manufacturing, Value Stream Mapping, Theory of
Constraints, GD&T, Gage R&R, QOS Facilitator &
Trainer, TQM, Autocad 2006, Microsoft Office .
IMPACT, EASE, AS400
Work Experience Specialized Skills
Turning : Okuma, Hardinge, Brown & Sharpe, Warner-
Swazey, Cincinnati, Traub, Fuji
Grinding: Cincinnati, Warner-Swazey, Browne &
Sharpe, Landis, Bryant, Heald, Nissei.
Machine Centers: Cincinnati-Milicron,
Lablonde-Makino, Mazak, Niigata, Chiron, Tsugami,
Fadal, Haas, Burgmaster, Hillyer
Dial Machines: Kingsbury, R&B, Lamb, Ann Arbor
Machine, Bullard,Turmat, Micron, Hydromat, Wurth &
griffith, Hahn & Kolb.
Transfer Lines: Standard, Lamb, Ann Arbor Machine
Automated & manual assembly& test lines & cells for
numatic valve, brake calipers, abs brake valves,
Brake proportioning valves, tensioners & Variable
Cam Timing .
Misc: Thermal Deburring, High Pressure Water
Deburring, Ultrasonic Cleaning, Vibratory
Deburring, Phauter & Gleason Hobs, Distech
automated material handling
May 2007-January 2009
Borg-Warner VCT Ithaca, New York
Senior Mfg. Engineer
. Qualifying automated machining cells for the
production precision engine timing components.
Includes developing control plans, FMEA's, IPPAP,
Job Aids, Operator instructions, process debug,
tooling design & improvement, operator training &
production support. Process improvements primarily
in tooling on existing equipment.
Nov. 2006-May 2007
. Camshaft Machine Jackson, Michigan
Senior Mfg. Eng,
Main focus: Cost Reductions thru continuous
improvement of tooling & processes.
May 2005-Nov.2006
Modern Solutions Contract to Harley-Davidson
Menomonee Falls, Wisconsin
Senior Mfg. Eng.
. Qualifying four new automated machining cells
for the production of precision
transmission components. Includes developing
control plans, FMEA's, IPPAP, Job Aids, Operator
instructions, process debug, tooling design &
improvement, operator training & production
support.
2003-2005
Ecommerce Business H & M enterprises
Sales Mgr.
Develop new customer base, customer service, train
& assist other associates in developing & growing
their own business.
.
1998 - 2003 TRW Automotive Fowlerville, Michigan
Senior Mfg / Quality Engineer
APQP utilizing Impact Software to generate PPAP,
Process Flow, FMEA, & Control Plans of new
products. Kept all documents updated to reflect
process changes & improvements.
Spc Coordinator: Monitored SPC data for 30
machining centers & final assembly line to ensure
that all process CPKs were at acceptable levels.
Initiated corrective action to ensure that process
would remain in control. Initiated 100 % inspection
& sort if Process was out of control.
Trained in Two week long Kaizen events led by a
Japanese Sensi & subsequently lead teams in lean
manufacturing events. Thru lean events a
continuous assembly line was broken into four cells
which increased production from 400 to 600 units
per shift . In another, a cost savings of $ 5,000
dollars a day was realized by determining that
major scrap was caused be pallet fixtures that were
manufactured out of specification.
Designed & built fixtures to Poke-Yoka assembly
line.
Designed & build checking fixtures & gages for
incoming material when necessary.
Work Experience 1986 - 1998 Trw Automotive Jackson, Michigan
Senior Mfg. Engineer
Brought eight new products on line Including
machining, assembly & test. Responsible for
coordinating acceptance of equipment at machine
builders plant run off, through installation and
final capability runs in house. Trained initial
operators & set-up people.
Ran tool trials to find methods to improve tool
life, productivity & cost.
Supervised tool room & assisted maintenance in
determining PM schedules.
Responsible for tool crib, establishing &
maintaining proper max min levels.
Daily responsibility of two machine & assembly
lines : troubleshooting, problem solving & process
improvements.
As TQM facilitator, trained 250 employees in
problem solving & continuous improvement methods.
Worked with quality engineers to resolve customer
issues & find solutions to mistake proof the
process.
Significant Cost Savings Achievements
Opportunity: Grommets on Brake Caliper assembly line not being consistently
assembled causing the addition to the line of one person on each of three
shifts .
Solution: Designed soft assembly grippers to simulate the action of the
human fingers reseating the grommets.
Result: 100 % reliability
Savings: 3 people @ $100,000/yr cost = $300,000/ yr
Opportunity: High tool costs & slow cycle time on deep hole drilling
operation on Aluminum ABS valve transfer line.
Solution: Replaced Indramat drill head utilizing a $100, 1/8" high
pressure coolant drill ( average breakage, 10 per day) with a
programmable Indramat drill head capable of peck feeding utilizing a
Standard Guhring $10 drill (average usage, 6 per day ).
Cost: $10,000
Annual savings: $250,000 in tooling, $25,000 in Scrap reduction, Cycle time
reduced by 25% ( From 40 seconds to 30 seconds)
Opportunity: Chain Broach tooling sharpened in house on manual grinders
utilized 2 cutter grinder on each of two shifts. Increased volumes would
require tripling exiting tooling & utilizing outside grinding sources to
maintain flow.
Solution: Purchase special 5 axis Star CNC cutter grinder
Cost: $300,000
Result: ROI 12 Months, One new set of tooling required instead of three,
One cutter grinder per shift instead of two, 40 % increase in tool life due
to quality of grind, no outside sourcing required.
1983-1986 Ross Operating Valve Madison Heights,
Michigan
Mfg. Engineer
. Cost estimates: Tooling, Processing, & Capital Equipment
requirements.
. Set up new processes in satellite plants.
. Refined & improved in house processes
. Designed assembly fixtures
Education A.A. Oral & Written Communication St. Clair Community College
Port Huron, Michigan
Journeyman Tool & Die Maker
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