Engineer Maintenance
Resume:
JOHN W. FALCONER
**** ***** ***** **. ***. ***, Pine Bluff, AR 71603
**********@*****.***
SUMMARY
BSIE & BSMATH with 10 years of experience in high volume, non-union automotive tier 1 suppliers.
Processes include: injection molding, stamping and high volume assembly. Utilized Kanban, Kaizen, lean
manufacturing methodologies.
EDUCATION AND NOTABLE TRAINING
Bachelor of Science, Industrial Engineering, 2000
Bachelor of Science, Mathematics, 1995
University of Louisville, Louisville, KY
• Lean Manufacturing trained, Hitachi, 2004
• FEMA trained by the Ford Motor Co., 2006
PROFESSIONAL EXPERIENCE
STANT CORPORATION, Pine Bluff, AR 2005 – 2009
High volume manufacturer of gas caps and thermostats for the automotive industry.
Manufacturing Engineer
• Pilot new fuel caps for OEM and aftermarket production.
• Led 2 Kaizen events, been involved with many Kaizen activities.
• Conduct capability studies for failures and route causes and report/implement findings.
• Updated and produce PFMEA’s and standardized work instruction on all fuel caps.
• Update and create all laser programs.
• Maintaining and updating current pad print operations, reduced the cost of purchasing a cliché by $700 per cliché by
insourcing the work, reduced changeover time by 40 percent and increased production by 20 percent per operator for
printing fuel caps by changing supplies, updating equipment, and enforcing cleanup procedures.
• Maintained and created vector testers programs for various pressures and vacuums performed on fuel caps.
• Create capacity studies for OEM’s based on their requirements.
• Used continuous improvement and lean activities to improve production cell production and reduce scrap and wasted
activity, improve OEE by 15 percent on most production cells, have achieved world class OEE and regularly maintain
world class on a few production cells.
• Updated floor layouts in the factory using AutoCAD.
• Update Preventive Maintenance sheets plant wide and insure preventive maintenance is being performed on all
production cells, reduced unscheduled downtime by 20% by designating team members and maintenance
responsibilities for machine maintenance. Reduced scrap by 60 percent by enforcing preventive maintenance
procedures.
• Trained others in 5S, Kanban, Standardized work, quick change over, and taking ownership of their work cells.
• Continually conduct time studies, tact times, and line balancing to find additional production improvements.
DANA CORPORATION, Commercial Vehicle Systems Division, Henderson, KY 2005
Industrial Engineer III
• Researched the use of robots to reduce the cost of production.
• Worked with quality control in implementing quality issues on the suspension line to reduce rework of finished truck
axles for Dana’s customers and reduce the cost of rework to Dana, developed a gauge to be used in welding to
position the accessories in the correct position for welding.
• Worked with Dana’s customers to find better ways to improve shipping quality, developed a supporting base that
reduced the number of damaged axles by 90 percent, worked with supplier in developing a better tool for their
production and reducing bad components sent to Dana.
• Found more efficient ways to improve the leak test done on axles, estimated savings of 40% by changing components
used in testing.
• Trained the production workers on how to use the quality controls implemented.
• Performed traditional time studies to update the standard times for the production lines.
• Worked on various continuous improvement projects and one Kaizen event
• Helped implement lean activities for controlling and reducing inventory.
• Research and tested Mylar tags to replace the metal id tags used in identifying axles for commercial trucks.
HITACHI AUTOMOTIVE PRODUCTS USA, Harrodsburg, KY 2002 – 2005
Industrial Engineer
• Championed for the company in the use of Ford’s and General Motor’s ideas and theories in OEE (Overall Equipment
Effectiveness) and TPM (Total Production Maintenance) and it application plant wide.
• Created an improved OEE and TPM program using Excel and Visual to create a more accurate production report and
an end of shift report, this program improved production by 40 percent.
• Trained supervisors, lead people, and anyone who would be using the Production program to enter in information and
those would be using the Production program to pull information out for other reports.
• Created a monthly, by yearly, and yearly monitoring OEE and TPM program using Excel and Visual Basic for the
Section Supervisors, Engineers, and other high ranking officials including the Plant President to keep pace with the
information from the Production OEE and TPM programs.
• Used Access and Excel in monitoring and maintaining a weekly Headcount Report and biannual Budget Report.
• Created an Access program for updating and monitoring all in house models and pass through models that the
company handles.
• Created other computer programs in Excel that supervisors and other industrial engineers used to keep track of
information in their departments and sections.
• Took over production lines that were once OEM lines that became service lines.
• Created production lines for the pass through products that comes from Japan and pass to Hitachi customers.
• Perform Time Studies to update the Standard Time’s for the service lines and for production lines that require an
additional inspection of final products.
• Created and updated Bill of Materials/ Routings for production and service parts
• Involved in one Kaizen event
CO-OP EXPERIENCE
AMERICAN PRINTING HOUSE FOR THE BLIND, Louisville, KY 1999 – 2001
Co-op Operations Engineer
• Created and updated Bills of Material/Routings for Talking Books, Large Type Books, and Braille Books using
Impact.
• Performed Time Studies to verify current standards in the plant.
• Updated Operation Descriptions for all operations.
• Redesigned floor plan for the maximum space utilization of Work Centers.
• Created Visual Flow Displays to show the flow of material and products from Work Center to Work Center.
COMPUTER SKILLS
• MS (Word, Excel, Access, PowerPoint, Project, Visio), Arena, AutoCAD LT, IDEAS (Integrated Design Engineering
Analysis Software)
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