Sign in

Engineer Manufacturing

Houston, Texas, United States
May 19, 2017

Contact this candidate

Michael D. Czapla

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

Katy, TX, 77493


Manufacturing Engineer /6 Sigma Black Belt

Summary of Qualifications

Bachelor’s Degree in Mechanical Engineering with 10+ years manufacturing engineering. 6 Sigma certified, Black Belt Candidate, Greenbelt and Kaizen.

Lean Manufacturing: Work Standards, Value Stream Mapping, Single Piece Flow, Waste Reduction, Time & Motion Studies, Just-in-Time Inventory, 5S, Kanban, Poka Yoke

Project Management: Project Selection- Cost Analysis, New Product Considerations, ROI through Project Realization – Define scope & deliverables, assign team & contractors, negotiate & Purchase Agreement, Project Delivery – Schedule downtime, install, train, document, & Project Hand-off

New Product Launch – Proof- of-Concept Prototypes, Design for Manufacturing (DFM), in automotive, Oil & Gas, and industrial electronics & sensors that comply with ISO 9001, NHSTA, API, ATEX, CE standards for product quality, traceability, and certification

Work Experience

PlyGem Windows – Bryan TX- 2015- current

Senior Process Engineer & Quality Manager

Reduce In-Process Scrap – save $1.2MM in internal scrap with cross-reporting and accountability. This lead to several projects to find Root Cause and eliminate more waste.

Lead 3 process engineers and 8 associates in Quality Control, mentored in Lean Six Sigma. Lead Kaizen events and ‘trained-the-trainer’ for other Kaizen and Green Belt projects.

Catalog Failure Modes and reduce failures – Enable Daily, weekly, monthly, and quarterly reporting for First Pass Yield and Internal QC for all 80+ product skews.

Direct interface with customer complaints in TX and the South East. Reduce warranty response to a week and resolved most issues within 4 weeks

Vallourec Drillpipe Products – Houston, TX -2014-2015

Continuous Improvement Engineer – Drillpipe Forging, Machining, & Welding

Process Improvement – Designed new forging tools for better pipe upset, which led to more stable set-ups, reduced downtime by 2 hours per change over.

Used the key metric of OEE – Overall Operation Efficiencies to train new supervisors in Lean, 5S, SMED, and other modern manufacturing management techniques

Projects Managed: development and installation of material handling automation – complete turnkey; Research & Cost-Analysis for proposed Capital Expenditures for new products/facility modernization

Weatherford – Artificial Lift Systems, Odessa and Katy TX 2012 – 2013

Lean Manufacturing Engineer – Launch new facility with an established engineered product

Launched new greenfield facility: Complete construction of facility: Industrial Building, Overhead Cranes, Paint Booths, CNC torch cutting, & welding automation.

Document assembly processes from historical sources in Odessa, design and verify new fixtures for fabrication & inspection,

Train the launch crew for new API Q2 (artificial lift systems – Pump Jack), facility was certified for API license in Fall of 2013

Metrix Instrumentation, Houston TX, 2010 – 2012

Sr. Manufacturing Engineer – Condition Monitoring Systems-compressor & pump applications

Increased production 25% without adding manpower -Rearranged work-cells for single-piece flow, simplified Work Order routers, began Kanban system with Vendor Managed Inventory to tap into ‘hidden factory’ and ‘tribal knowledge’.

Reduced Scrap 10% by using Design for Manufacturability- Added GD&T to Product Design, trained suppliers to meet our new machining requirements.

Product Launch for Machinery Protection System – Supplier auditing, prototype planning, writing instructions, training associates, packaging design.

Toshiba International Corporation, Houston TX, 2008 – 2010 Manufacturing Engineer – Electric Motors to 800 HP

Launch new product expansion with minimum expense and loss time.

Work Standards- with shop floor associates, documented assembly processes in words in pictures for Standard Work.

Project Management – evaluate and install upgrades to furnace processes

Develop and improve manufacturing processes for large electric motors, Research for Process improvement: honing versus burnishing, grinding versus lapping.

Ford Motor Company 1999 – 2008

Manufacturing/Industrial Engineer, Econoline Van, 2007 – 2008

Improved Significant Concerns and First-Time-Through. Reduced Warranty concerns from 202/1000 Things-Gone-Wrong to 101/1000 TGW Completed Black Belt 6 Sigma training and started 2 BB projects that should save $500,000 in warranty claims

Reliability/Quality Engineer, Powertrain – Automatic transmission 2006

Powertrain Development: Torque Converter: SuperDuty 5R110 MY 2008

Evaluated test results from prototype components; Using Design of Experiment (DoE) and Design for Six Sigma, tested torque converter designs.

New Product Engineer/Vehicle Integration Engineer, F150 MY2008, 2005

Raptor F150 -Built 4 prototypes, managed a fleet of 60 prototypes, scheduled testing and maintenance

Studied the truck segment to define Best Practices & Benchmarks, using Consumer based 6 Sigma. Within the Vehicle Engineering Group researched relevant data for decision makers on how best to proceed to targets, using competitive study, cost controls, and market data.

Manufacturing/Industrial/ Product Launch Engineer, New Plant F150, 2003-2004

Launched the Brand New State-of-the-Art Dearborn Truck Plant for MY2004

Exposure assignment as Human Resources Associate at Dearborn Assembly (Rouge Assembly Plant, home of the Mustang until 2004). While in the Human Resources department, transferred employees to the new plant as it came on line; while interviewing, hiring, and placing 1500 temporary employees to backfill the transfers to the truck plant. Quality (FTT) and production were never better than with the temporary crew.

As Plant Engineer investigated breakdowns and production concerns daily, answered for production losses, brought plant on-line to planned targets, through line speed management, process flow, model balance out.

Launch Engineer and Production Supervisor, Norfolk Assembly Plant, 2002

Production Supervisor of Final Area making current model, balanced out model

As Material Replenishment Engineer, rearranged Final Area material flow during shutdown and ramped up new model

As Launch Engineer, contained 60 days of production units for quality, ran a fleet of 100 trucks to gather 1.3 million miles, responded to executives' concerns with new model truck.

Launch/ Engineer, Expedition/Navigator, 2001

Launched new tooling, including 6 axis alignment pre-set tool.

Redesigned layout of shop floor for additional product complexity.

Powertrain Engineer – Structures 2001

Developed extension housing for 5-speed truck transmission for Super Duty trucks and vans, saved $3 per unit by changing manufacturing process, total to $10 million savings to the life to the program

Assistant Engineer – New Model Launch 3.0L EngineS, 2000

Manufacturing Engineer as cylinder-head manufacturing line, converted machinery form 2.5L to 3.0L/2.5L Escape, efficiency studies, production trouble shooting. Solved problem of false positives on test stand, 10% increase in through-put.

Education -BSc Mechanical Engineering

University of Detroit-Mercy, Detroit, Michigan, 2002

U.S. citizen with passport

Other Engineering skills:

Tools/Skills: Global 8D, FMEA (Failure Mode and Effect Analysis) Process-FMEA and Design-FMEA, Process Controls, SPC, 6 Sigma, and Kaizen events; also annual internal and external ISO 9001 and 14001 audits, TS 16949. Lean Manufacturing: TPS’s Safety-Quality-Delivery-Cost, Value Stream Mapping, 5S,Mintab Kanban, Poka-Yoke, Line Balancing, Visual Factory, Fishbone Diagrams. Pull Production, Taguchi Methods, Root Cause Analysis. Material Replenishment Principals: FIFO, JIT, Tip Level, Ppk. DOE (Design of Experiments), Supervisor, Superintendent, Operations, ROI, API, American Petroleum Institute, Operational Excellence, OSHA, Gemba Walk, Finite Element Analysis, DEFORM software, AWS, Hoshin Alcona

Interests: First LEGO League, Detroit Area Pre-College Engineering Program (DAPCEP), foster parenting.

Contact this candidate