Engineer Process
Resume:
Thomas J. Przybysz (p-shib-ish), P. E.
**********@*****.***
MANUFACTURING/PROCESS ENGINEER
MECHANICAL/ELECTRO-MECHANICAL
Manufacturing/Process engineer with experience in component/subassemblies, wave soldering and final
assembly areas with a major automotive parts supplier. Manufacturing/Process experience includes
development of process flow diagrams (PFD’s), process control plans (PCP’s), process failure mode effects
analysis (PFMEA’s), set-up cards, work instructions and process validation. Additional experience includes scrap
reduction through FTQ and OE improvements, equipment procurement and the supervision of manufacturing
and test engineers.
CORE COMPETENCIES/SKILLS
Six Sigma Experience
Error-proofing Preventative Maintenance
Production Support Problem Resolution C/A Implementation
PFMEA’s PPAP Process Control Plan (PCP)
Process Flow Diagram (PFD) First Time Quality (FTQ) Operational Efficiency (OE)
EDUCATION
M.S. in Engineering Science of Management of Technology
Rensselaer Polytechnic Institute, Troy, NY
B.S. in Mechanical Engineering
Michigan Technological University, Houghton, MI
Professional Engineer (License #620*******)
State of Michigan
EXPERIENCE
DELPHI, Electronics and Safety Division, Flint, MI 48556
Product Development Engineer (2007 to 2009)
Provided electromechanical engineering support for current production automotive instrument clusters, such as
the Silverado, Impala, Lucerne, Monte Carlo, Trail Blazer and Ford Mustang Bullitt.
Investigated, analyzed and summarized customer readability complaint on the Lucerne instrument
clusters then proposed an LED lit instrument cluster to replace the current lamp lit cluster.
Implemented bolder graphics on the Lucerne instrument clusters to improve readability.
Successfully evaluated and negotiated the requirements of LED lit instrument clusters for the Lucerne,
Impala and Monte Carlo programs then implemented them.
Directed the efforts of design engineers in the development of 2D and 3D models that used Unigraphics
software similar to Solidworks and Pro-E.
Supervisor, Final Assembly & Test Group (2005 to 2007)
Supervised the daily activities of controls and manufacturing engineers to improve FTQ and OE by setting
priorities, defining long term goals, equipment responsibilities, and conducting performance reviews.
Improved first time quality (FTQ) on the Trail Blazer (GMT360) assembly line by directing the root cause
analysis and corrective action for high stake forces.
Improved operational efficiency (OE) on the Harley-Davidson assembly line by supervising the
installation of software for high volume part numbers on a back-up assembly line.
Directed the error-proofing on the GMT530 assembly cell that eliminated the spike in customer
complaints for the plant.
Implemented department ESD audits and ionizer PM’s to prevent damage to electronic components.
Thomas J. Przybysz, P.E. 810-***-**** Page 2
Rewrote procedures and forms for programming product memory and storing machine software.
Process Engineer - Wave Solder (2002 to 2005)
Responsible for maintaining and optimizing wave solder processes for First time quality (FTQ) improvements
and scrap reduction on circuit boards (CB) for automotive instrument cluster assemblies.
Improved operational efficiency (OE) of the wave soldering processes by soliciting skilled trades’ input
then reviewing and updating the PM plans accordingly.
Implemented new process materials, such as organic CB coating and Cobar® flux.
Designed and developed process tooling, such as lead clearance gauges and set-up templates to aid
operators and skilled trades.
Manufacturing Engineer (1995 to 2002)
Responsible for making tooling modifications for error-proofing, operational efficiency (OE), and First Time
Quality(FTQ) improvements on automotive instrument cluster assembly and test equipment in addition to
creating and updating process flow diagrams (PFD), process control plans (PCP) and process failure mode
effects analysis’ (PFMEA’s).
Developed and installed error proofing on the Buick LeSabre final assembly cell to detect misassembled
lenses.
Eliminated damage to the LeSabre, Impala, Monte Carlo, Transport, Silhouette, Lumina instrument
clusters due to the appliqué press.
Improved FTQ (reduced foreign material) by installing lens air scrubbers on the above final assembly
lines.
Improved OE on the LeSabre final assembly cell by installing a new, smaller nosepiece on the auto feed
screwdriver.
Reliability Engineer (1988 to 1995)
Responsible for environmental testing of electromechanical odometer assemblies, small metal parts and die-
castings for the Production Part Approval Process (PPAP).
Created the mechanical odometer test specification (C-4015), as well as, specific test methods for
temperature/humidity testing and sound measurement (Q1000-226).
Used Weibull techniques from life testing to analyze and determine acceleration factors for temperature
and humidity on electromechanical odometer assemblies.
Trained fellow Parts Reliability Engineers to perform PPAP audits at supplier’s sites.
Audited suppliers for Dimensional Measurement Accreditation (DMA).
General Dynamics Corporation, Land Systems Division, Warren, MI 48090
Reliability Engineer (1985 to 1988)
Lead reliability engineer on concept armored vehicle programs for the U. S. Army, such as the Armored
Recovery Vehicle (ARV) and the Electro-thermal Gun.
Wrote and coordinated reliability proposals, provided inputs to test plans as well as planned staffing.
Developed and coordinated reliability predictions, math models, allocations and failure criteria.
Monitored vehicle design and performance by reviewing drawings, scoring test incidents and used a
closed loop reporting system to drive corrective actions.
Westinghouse Electric Corporation, P.G.S.D., Minneapolis, MN 55416
Field Maintenance Engineer (1981 to 1985)
Provided lead technical assistance for major maintenance of steam turbine-generators. Maintenance consisted
of aligning shafts, checking clearances, welding/machining operations and non-destructive evaluation (NDE) of
vital components.
Directed skilled labor during disassembly, inspection, repair and assembly procedures.
Wrote customer reports detailing the inspections, repairs, and recommend future repairs.
CREDENTIALS & REFERENCES AVAILABLE UPON REQUEST
TECHNICAL ADDENDUM
for
Thomas J. Przybysz (p-shib-ish), P. E.
(810) 695 – 5752
**********@*****.***
Product Engineering
Design Development Engineering Change Release DFMEA
Print Change/Creation BOM Change/Creation Product Support
DFSS DVP&R GD&T
PPAP Directed 2D/3D Model Development L*a*b Color Coordinates
xy/u’v’ Color Coordinates
Supervising/Process/Manufacturing Engineering
Error-proofing Corrective Action Implementation PFMEA
Preventative Maintenance Problem Resolution Machine Cycle Time
Drill Deep/Wide 5 Phase C/A 5 Why
Process Flow Diagram First Time Quality Process Control Plan
(PFD) (FTQ) (PCP)
Speedline Vectra Operational Efficiency Cookson 650
Wave Soldering (OE) Wave Soldering
RCFA
Reliability Engineering
Weibull Analysis Accelerated Life Testing Environmental Testing
Shainin Reliability Reliability Predictions Block Diagrams
Math Models Allocations Test Scoring
Shainin Problem Solving
Maintenance Engineering
Report Writing Shaft Alignment Oil Analysis
Vibration Analysis Blueprint Reading NDE/NDT
Clearance Measurement Hydraulic Control Systems Directed Skilled Trades
Steam Turbines Harmonic Analysis
Software Computer Skills
Business Engine Network Global Engineering System MAXIMO
(BEN) (GES) (CMMS)
Minitab Lotus Notes MS Office
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