RODNEY D. MAYBERRY

**** **** ***** **** **

New Castle, Indiana 47362

Home: 765-***-**** / Cell: 765-***-****

E-mail: abnun5@r.postjobfree.com

CAREER SUMMARY

Hands-on experience in tool, manufacturing and facilities engineering, and project management. Innovative

conceptual designer, acutely cost-conscious, with proven ability to complete projects within budget

constraints. Creative leadership ability to strategically plan and control objectives, and budget administration.

Capable coordinator of interdepartmental activities. Excellent results-oriented supervisory approach that

encourages technical and skilled personnel. Works effectively with all personnel and management levels

toward accomplishing set goals in a timely fashion.

PROFESSIONAL EXPERIENCE

Project Manager/Mechanical Engineer/Tool & Process Engineer Nov 94 to Mar 09

Chrysler Corporation, Kokomo, IN and New Castle, IN

Spearheaded projects involving design, development, and installation of machining and assembly

processes for high volume, precision automotive components.

Supervised 10 to 15 maintenance personnel during continuous improvement projects, process

changeovers and tooling installations.

CNC programming of vertical and horizontal machining and turning centers on precision components.

Skilled in centerless grinding, hobbing and broaching of various automotive components.

Supported heat treat and controlled carburizing operations.

Charged with engineering and project management responsibilities in the areas of automated parts

conveyance, material handling, and parts packaging.

Followed ergonomic methods to reduce operator injury and waste of motion.

Designed and installed plant air quality systems including new air handling units, process mist collection

and ductwork, fluid mechanics including pump sizing and piping schematics of washers and coolant

systems, and energy management.

Applied lean manufacturing techniques in problem-solving teams, implementation of 5S, mistake proofing,

and improving process flow by evaluating throughput and reducing bottlenecks.

Involved in 6-Sigma through Quality Function Deployment groups, PDCA cycles, 5-Why Analysis, Pareto

charts, and process flow diagrams.

Led Project Action Team on 488 shaft line.

Reduced lost builds by 51% or an average reduction of $16,924/month.

Overtime reduction of 277 hours/month or $189,468 annually.

15.8% Throughput Improvement.

Responsible for feasibility studies, writing projects, cost estimations, funds appropriations, and

management of project funding.

Actively involved member of Total Preventative Maintenance (TPM) and Throughput groups.

Served as cross-functional team member in the launch of the 62TE transmission with responsibilities for

process layouts, ordering equipment, qualifying processes, and training personnel.

Received 2005 Chrysler Environmental Leadership Award for process to reclaim machine coolants.

Analyzed operations and implemented improvement procedures adding value, cutting cost, and improving

customer satisfaction.

Engineered and implemented changes in the acid dip tanks’ water flow control that resulted in a 0.4 year

payback and a $50,000 annual savings.

Specified and installed $5 million dollar powerhouse renovation including new Ingersoll-Rand centrifugal

compressors, Cleaver-Brooks package boilers, and BAC cooling towers and pumps.

Created process layouts for new and existing processes with a focus on lean manufacturing, constraints

management and Kanban systems.

Initiated continuous improvement ideas on process lines by utilizing the 5-step improvement process and

Kaizen process of improvement.

Implemented changes in broach bar design and fixtures that reduced brake support flex for an annual

rework and scrap savings of $200,000.

Utilized Gantt charts and CPM to manage production and facilities related projects.

Mayberry - 2

Coordinated projects with multiple departments and led skilled trades’ personnel and subcontractors

toward on-time project completion.

Assisted in implementing QS-9000 initiatives.

Specified and purchased production equipment and verified process capability.

Maintained tool and operations documentation, and created SOPs to communicate process.

Applied SMED methods to fixtures and tooling to cut changeover times on average from 4 hours to 15

minutes on batch processes.

Replaced five machines with one machining center/drill press cell on the caliper line for a $210,000 annual

savings.

Executed tool life studies and made process improvements to increase uptime and reduce scrap.

Conducted process FMEAs for new processes.

Used SPC to measure and control product quality.

Utilized SURFCAM software in machining forging dies for prototype parts.

Practiced tooling and fixture design using GD&T, and gages that meet gage R&R verification.

Designed special tool holders and chucks for heavy duty brake hubs that reduced tooling costs by $60,000

annually and part handling by 50%.

Manufacturing Engineer Feb 93 to Nov 94

Dayton Walther, Carrollton, KY

Maintained documentation and reduced perishable tooling costs.

Designed tooling, fixtures, gages, and process layouts from concept to completion for both new and

existing production.

Employed ASME Y14.5M GD&T standards.

NC programmer for the entire plant. CNC programming of vertical and horizontal machining centers and

turning centers using Conventional, Conversational, and Parametric Programming methods.

Applied parametric programming methods reducing the number of CNC programs thereby reducing setup

time and improving process flexibility.

Automation experience using Allen-Bradley PLC.

EDUCATION

Masters of Business Administration – Finance

Indiana University, Kokomo, IN 46904

Estimated Completion: 9 credits hours remaining (GPA: 4.0/4.0)

Bachelors of Science Mechanical Engineering Technology

Purdue University, West Lafayette, IN 47907

CONTINUED EDUCATION

AutoCAD 2006 2D & Preliminary 3D

Fanuc 15T control training on a Motch Turning Center

Mazak Mazatrol M-32B control training on a Mazak machining center

SME Parametric Programming course on Fanuc controls

Kepner-Tregoe Root Cause Analysis/Problem Solving

Failure Mode and Effects Analysis

Intermediate Geometric Dimensioning and Tolerance

Fundamentals of Measurement for Chrysler

Intergraph Microstation 2D Graphics Level 1

Ingersoll-Rand Course 905 Basic Mechanical Disassembly and Repair

DaimlerChrysler Energy Management Best Practices Symposium

49th Annual Ventilation Air Conference - Michigan State University

Goldratt’s Theory of Constraints

COMPUTER SKILLS

Engineering Tools: AutoCAD 2007, Microstation, SURFCAM, and Minitab.

Business Tools: Microsoft Office, Microsoft Project and Adobe.

ACTIVITIES

Member of Society of Manufacturing Engineers

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