Project Manager Engineer

DAVID A. TODD *** Morning

Star Drive

Home: 937-***-****

Marysville, OH 43040

Mobile: 937-***-****

abna17@r.postjobfree.com

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CAREER SUMMARY:

Over eighteen years of engineering and manufacturing experience with

continued success in the development, evaluation and improvement of

production processes including the process management and leadership of

people in Six Sigma, Lean Manufacturing and TPM environments in various

industries. I have career experience in supplier and customer quality, new

product launches, TS16949, ISO9001 and QS9000. Trained and practiced in

problem solving techniques such as 5Y, 8D, 5P (Honda), DMAIC, DOE, PDCA,

SMED, Process Mapping and FMEA.

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WORK EXPERIENCE:

Manufacturing Engineering Manager: Sypris Technologies, Kenton, OH.

(Plant closed) (June 2007- March 2009)

Managed five engineers consisting of various disciplines for heavy axle

manufacturing for the trucking industry. Developed training program for

TPM / Lean Implementation in a CNC machining and welding environment.

Jointly led root cause analysis efforts with the Quality group.

Responsible for APQP compliance, documentation and requests for quotes

and product launches. Justified and led capital projects for on and off-

site installations including the use of FMEA. Assisted in planning and

leadership of Maintenance group (20+ people). Led efforts to in scrap

reduction in forming/area, reducing scrap by $220,000 annually Lean and

Six Sigma techniques. Assisted in the resolution of supplier and

customer quality issues. Member of transition team to relocate business

and participate in PPAP's. Conducted and participated in TS16949 audits

and activities.

. Project Manager for $1.8 million in cost savings projects through

Profit Protection Program.

. Led efforts for cycle time reduction and quality improvements for CNC

machining.

. Led plant wide Continuous Improvement efforts in product and

processes.

Lean Manufacturing Engineer / SWI Coach: Daido Metal Bellefontaine,

Bellefontaine, OH (June 2002- June 2007)

(2004-2007) Member and key change agent of the Lean Implementation

Department. Team Leader in creating and implementing Standardized Work

Instruction/Standard Work Program and Leader of Set Up Reduction Program

relating to metal stamping, forming and cutting of automotive bi-metal

bearings for crankshaft applications. Assisted in development of TPM

Program. Led and assisted in facilitating and supporting 5S and TPM /

Kaizen / SMED events. Provided engineering, training support and design

review for five manufacturing cells (45 people) including 5Y and PDCA.

Mentor/coach new Value Stream Leaders in team efforts and problem

solving. Certified in Lean Manufacturing through the University of

Kentucky's graduate program. Trouble-shoot & modify P.L.C. programs for

equipment. Justify and coordinate capital projects. Re-designed process

layouts for efficient use of space and effective flow of materials. Team

Leader for SMED/ Set Up Reduction efforts, saving an estimated

$210,000/yr. through tool and fixture designs. Addressed supplier and

customer quality issues. Trained and practiced in 5P as a supplier of

Honda of America Manufacturing.

. Reduced set time for linked cell by an average of 47% through process

mapping and procedure changes.

Tool Room Supervisor / Six Sigma Blackbelt: (2002-2004) Managed three-

shift tool room operations consisting of 27 tool makers and machinists.

Developed training programs for CNC and manual milling, grinding and EDM

Wire, conducted employee assessments and counseling. Initiate design

changes to improve product quality and tool life. Justified capital

expenditures for equipment purchases and rebuilds. Responsible for budget

creation and management. Improved Tool Room fabrication processes saving

$57,000/year. Addressed supplier and customer quality issues.

. Created programs to calculate and track in-house tooling costs

including labor hours, material and treatment costs.

. Produced tooling requirements forecasts for Bearings Manufacturing.

. Reduced department spending by an average of 50%, while improving

inventory of supplies and materials.

. Team Leader for Six Sigma project saving $27,000, with results to be

duplicated in others areas for a total savings of $130,000.

DAVID A. TODD

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Manufacturing Manager: ReaderVision Div., Kernersville, N.C. (sold &

relocated) (Sept. 1999 - Sept. 2001)

Lead Production (as Value Stream Manager), Purchasing and Inventory

Control teams, scheduling, shipping and receiving and Process Improvement

for start up venture manufacturing electro-mechanical message centers in

Lean environment (20+ people). Developed training programs, conducted

employee assessments and counseling. Researched applications and

implemented the use of reflective and adhesive films. Shared

responsibility for the compliance with OSHA regulations. Responsible for

budget creation and management. Assisted in the resolution of supplier

and customer quality issues. Led supplier qualification efforts. Led

line balancing efforts. Facilitated 5S events and 5Y training.

Participated in product design and testing.

. Increased production capacity over 600% and eliminated production

capacity as an obstacle to product sales by balancing assembly

processes, increasing efficiency of product flow, and standardized

work.

. Reduced assembly and rework times by 30%, and improved product

reliability by developing training program and standard work

instructions for all areas of assembly and through vendor development.

. Reduced inventory levels by 64% through vendor development and

inventory program implementation.

. Achieved as much as 50% component cost reductions through purchasing

practices and design modifications.

. Member of cross functional team, including Design Engineering,

Manufacturing and Marketing that launched next generation of product.

Manufacturing Engineer/Six Sigma Black Belt: Eaton Corporation, Roxboro,

N.C. (Sept. 1998 - Sept. 1999)

Designed tooling and material handling systems for high volume machining,

grinding and assembly equipment in the manufacturing of automotive engine

lifters and piston valve components. Monitored and maintained tooling

costs for Grinding Departments. Led three shift Production Team Meetings

and Root Cause Analysis efforts consisting of production, maintenance and

quality associates (40+ people). Qualified in QS9000. Justify and

coordinate capital projects. Conducted vendor certifications.

. Coordinated Six Sigma team actions in cost savings projects producing

an estimated $80,000/yr. in cost avoidance and projected savings of

over $320,000/yr. in abrasive and tooling costs and quality

improvements using DMAIC methods, including DOE.

. Established procedures, work instructions and conducted training for

new product launch.

Lead Manufacturing Engineer: Engineered Controls International, INC.Elon

College, N.C. (Layoffs)(Oct.1994-July1998)

(1996-1998) Managed Manufacturing Engineering Department (6 engineers).

Evaluated new product designs and design changes for tooling and

automation requirements for gas and cryogenic valves and regulators.

Practiced Concurrent Engineering in improving the machining, assembly and

testing of product assemblies. Duties included the troubleshooting of

assembly machines, processes and creation/maintenance of bills of

materials. Designed and coordinated the construction of assembly lines,

electro-plating and electro-static painting lines using in-house and

contract personnel. Conducted training for new equipment and processes.

Responsible for budget creation and management. Led or participated in

line balancing efforts.

. Project manager, justified capital for the purchase, or in-house

fabrication of automated machines and equipment for new and existing

assembly lines resulting in labor savings usually in excess of

$200,000 per year each.

. Developed and managed all aspects of the disassembling, shipping and

installation of new and existing production systems for new facility

layout design and start up using in-house and contract personnel.

Manufacturing Engineer: (1994-1996) Designed tooling and fixturing for LP

gas, compressed gas and cryogenic valves and regulators. Designed and

fabricated semi and fully automated assembly machines and assembly line

layouts. Duties included the troubleshooting of assembly machines and

processes.

DAVID A. TODD

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Director of Quality, Engineering, EHS & Maintenance: Lyon-Shaw Company,

Salisbury, N.C. (Merger)(June 1993-Oct. 1994)

(1994) Managed Quality and Engineering in Fabrication, Sub-Welding,

Final Welding, Finishing, Painting and Packaging Departments in the

manufacturing of steel furniture. Directed the Maintenance and R&D

departments (32 people). Responsible for the creation and maintenance of

bills of materials. Responsible for improvement and trouble-shooting of

electro-static paint system.

. Established and maintained quality control standards and investigated

customer complaints.

. Developed Quality data system to assist in root cause analysis and

project prioritization.

. Led team consisting of Production Supervisors, and Operators in root

cause analysis of issues in processes.

Engineer/Director of Safety& Maintenance : (1993-1994) Designed

tooling and fixtures for the steel forming and welding for steel

furniture. Conducted time and motion studies to establish pay rates and

to evaluate process flow design. Estimated material and labor costs for

new product lines. Responsible for company compliance with OSHA and EPA

regulations. Directed the Maintenance and R&D departments.

Performed troubleshooting for finishing and paint systems.

. Revised bill of materials, saving $18,000 per year ($180k potential)

by standardizing tooling and product components.

. Reduced packing/shipping errors by 31% by balancing packaging

department layout and defining inspection procedures.

. Developed facility safety manual and evacuation procedures.

Manufacturing Support Coordinator: Fenestra, Inc., Harrisburg N.C.

(Division closed) (Jan. 1992-June 1993)

Provided support service to production for uninterrupted flow of raw

materials in the production of custom and standard hollow sheet metal

doors, windows and frames. Purchased tools, supplies, and essential

services in a timely manner. Controlled and audited total inventory in

general accordance with JIT, MRP, and TQC.

Utility Machine Operator/Assistant Engineer: (1992) Trained in the

set up and operation of press brakes, punch presses and door assembly.

Conducted time motion studies. Assisted engineers with various projects.

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EDUCATION: B. S., Manufacturing Engineering Technology, Western Carolina

University, Cullowhee, N.C. (1991)

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CERTIFICATIONS & AWARDS: Certified Manufacturing Technologist, Society

of Manufacturing Engineers

Lean Systems Certification, University of

Kentucky

Certified Six Sigma Black Belt (CSSBB), SBTI

and Robbins International, LLC

Society of Manufacturing Engineers President's

award for Outstanding Service

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