Engineer Quality

ALDO ORRICO

* **** ******

Trumbull, CT *****

Home: 203-***-****

Cell: 203-***-****

Email: *********@***.***

SUMMARY

I am skilled in the segments of production operations with hands on working experience. I have Industrial and

Manufacturing Engineering expertise in the areas of component fabrications, electronic and mechanical

assembly, final and secondary operations, injection molding, prom programming in a clean and static free

manufacturing room. I have verified and validated manufacturing processes, procedures, product and

component design. Extensive experience identifying and implementing process, quality, and cost improvements

in support of value added, lean manufacturing, continuous improvements, kanban, 5S, six sigma, one piece

flow, and world class manufacturing techniques. As a product manager and engineer I was responsible for over

200 product launches from conceptual design through end of product life. Conducted project core team

meetings, reviewing time frames, total costs, overruns and overall project responsibilities. Resolved quality

issues internally and externally in support of improving Customer Satisfactions. Proven leadership and

communication skills from working with shop floor personnel to senior management. Excellent skills in both

proactive and reactive problem solving. Skilled in leading, training, coordinating and mentoring of team

personnel.

WORK EXPERIENCE

Currently working, Victorinox – Swiss Army Crop. Monroe Ct. (Jan 2010 - Present)

Industrial Mfg. Engineer – Warehouse Operations

• Developed optimum process flow for Receiving, and Pick, Pack, and Ship areas

• Developing layout and storage configuration to optimize flow racks and pallet capacities.

• Developed process labor times, bills of material and costs, manufacturing documentation, and work

instructions for in-house packaging equipment (Vertical Cartoner, and Blister machines)

• Developed a bonded warehouse location layout and requirements per government regulations.

• Reducing and redesigning the number of corrugated cartons for multi use packaging

• Developing process flow mappings for documenting cost and process improvements.

• Developed and maintain manufacturing balance charts detailing product work flow and sequencing.

MERISEL COPR, New York City (Temporary assignment – November 2008 – January 2009)

Manufacturing / Industrial Engineer

• Developed plant layout and consolidated the New York production operations into the Edison NJ

faculty. I have identified and implemented process and material flow improvements for product

savings and production efficiencies. (Production lead time was reduced by 25% by implementing work cells.)

• Developed work/process/quality SOP’s instructions for multi imaging printing production, quality

testing, customer data, packaging/shipping requirements, workmanship acceptance criteria’s.

• Identified and implemented cost savings by redesigning product packaging, combined printing and

mounting operations into work cells which improved manufacturing processes, and material flows.

• Established and maintained labor takat times and work standards. Performed production line

balancing per demand schedule and operational sequence times.

• Developed Process/Value Cost Mappings detailing Customer Service and Sales logistics flows.

PITNEY BOWES, Stamford, CT (October 1983 - May 2008)

Mfg. Operations Mgr./ Process Engineer / Manufacturing Supervisor

Managed a product line operational budget of $25 million in multiple facilities with 350 employees, was the

Product Manager responsible for developing product cost, quality, production, and market demands. Interfaced

with vendors to negotiate optimum cost, quality, and on-time deliveries. Prepared make vs. buy analyses, and

develop capital improvement proposals. I was responsible for managing and launching the total product life

cycles for 208 products and consumer goods from market research, prototype designs, manufacturing

production setup, market launches, total costs, customer experiences, and to product end-of-life cycle. I

generated work plans, timelines, budget KPI;s, scheduled and conducted project meetings for overall product

results, schedule attainment, and team coordinator interfacing with marketing, quality, engineering, production

personnel. Participated in Design-to-Cost and Design-to-Unit-Production-Cost programs.

• Implemented an average of $2 million per year of cost savings and cost avoidances that directly

reduced and improved product costs, process flow, quality, and the actual bottom line cost profitability.

(designed assembly holding fixtures, automated production line by installing equipment - air tooling,

parts washers, ultrasonic cleaner, carton sealer, lifts)

• Managed and supervised an exempt staff of 9 Industrial Engineers, and 14 Analysts, conducted

performance reviews, developed performance objectives per operations goals, and provided coaching

and mentoring for career advancement.

• I have developed and prepared labor and cost quotations for internal and external work requirements,

labor takt time standards, process documentation, production line, workload tasks balancing, quality

procedures, workmanship criteria, utilization and efficiency performance reports, bills of materials

revision control, labor and material flow analyses. Performed capacity planning and production work

studies for optimum cost and flows. Developed and implemented process/value stream cost mapping

using value engineering techniques.

• Responsible for the line of business products for re-manufacturing, final line production, and parts

assembly operations in multiple locations. Conducted site visits for manufacturing and quality audits,

product launches, cost improvements, and customer demand. (Newtown CT, Miamisburg OH, and

Bartlett TN. facilities)

• I have estimated and developed production hours, tooling costs, engineering costs, quality costs,

packaging costs, generated capital investment proposals, developed make vs. buy decisions, risk

analyses, cost payback calculations, travel costs, transportation costs, facility costs, product costs,

tooling and engineering sustaining ratios, inspection ratios, material allowance factors, program

management, configuration management, government regulations, distribution and logistics

• Reviewed all production drawings, specifications and procedures related to estimated and final product

cost, quality, and production matrix.

• Responsible for overall process cost control and quality budgeted targets. Prepared product cost and

quality process yields monthly summary reports for management overview.

• Developed a Direct Return Program for all final line products and replacement components resulting in

annual savings of $8 million.

• Identified and implemented process improvements and cost enhancements for lower product cost.

• Improved overall customer experiences - conducted weekly meetings with manufacturing facilities, call

centers, field reps, and marketing groups for problem resolution and corrective action implementation.

• Coordinated the development, design, cost justification, and marketing analysis, for the introduction of a

new product line of stand-alone and mechanical scales for Staples, Office Depot, and Office Max.,

generating $600,000 in annual sales.

• Developed product out sourcing and relocation process cost comparison matrix – successfully in-

sourced print head assembly, generated cost savings of $450,000.

• Conducted monthly MRB (materials review board) meetings; investigated and identified product failures

by reviewing quality reports, audits, process yields, statistical process control data, design of experiment

(DOE), failure mode and effects analysis (FMEA) and design for manufacturing (DFM) techniques, and

implemented corrective action to eliminate product failures. Measured and reported monthly quality

metrics to management and drove improvements per review.

• Reviewed and implemented all Engineering Design Change Notices and Engineering Change Orders

for all small business unit products.

Process Engineer IV / Sr. Industrial Engineer / Manufacturing Engineer

Responsible for new product launches from core team concepts, manufacturing and through final production

release to market. Total responsibility for product cost, quality inspection, complete production documentation,

accurate labor standards, product safety procedures, personnel training, product field performance, and

customer issues resolutions. Designed and implemented manufacturing production lines layouts for optimum

process flows, production line balancing, quality, safety, utilization, cost efficiency, and ISO/ BSI/ UL compliances

for maintaining or revising plant certification.

• Designed and implemented a warehouse racking and shelving layout which increased pallet capacity by

30%. Increased pallet storage locations from 600 to 790.

• I have developed used approved estimating methods and source data to prepare and present results in

an organized format and with sufficient detail to facilitate project, product, production and labor

performance review with management

• Designed and implemented assembly line layouts in support of production demands, product flow, and

cost. Eliminated bottlenecks by material layouts, designed assembly tooling aids, and revised work

instructions and quality procedures.

• Developed staffing requirements in support of production costs and demand schedule.

• Developed warehouse parts reclamations program for parts reuse, cost avoidance, and space

reductions.

• Subject Matter Expert for black belt projects with $800,000 in cost savings. Trained in Black, Green belt

training, SPC, ISO, SAP, CIS, Geometric Tolerances, Designed for Assembly, Process Value Cost

Mapping, Value Engineering, Gain sharing, GMP.

• Implemented the Improshare Process Improvement Gain Sharing Program for 1200 employees,

developed payout procedures, cost yields, and conducted program training for all personnel.

• Trained shop floor personnel in manufacturing and quality modules in support of world class

manufacturing and continuous improvement.

• Developed and created engineering and manufacturing documentation including engineering drawings,

assembly drawings, product specifications, product parts bills of materials, part and product

configuration, material change review, part structuring, and process/product testing procedures.

• Developed accurate labor and material cost quotes by evaluating product and component specification

drawings.

• Developed and designed cost efficient and ergonomic product packaging with $210,000 in cost savings.

• Certified WOFAC work measurement labor standard program instructor. Conducted training to all

Engineers in developing and implementing accurate labor and production costs. Conducted document

training in the development of process plans, SOE’s, SOP’s

• Power user/trainer for the SAP manufacturing module, added part cost, labor times, bills of materials,

process plans and work instructions, and quality procedures.

EDUCATION

BS, Business, Sacred Heart University, Fairfield, CT

Bridgeport Engineering Institute, Mechanical Engineering

COMPUTER SKILLS

Microsoft Excel, PowerPoint, Access, Project, Visio, SAP, AutoCAD, Wind-Chill, SmartDraw,

WIP, MANMAN, MRP/ERP, CIS. CAPP

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