Engineer Lean Manufacturing

TERRY R. KEYS

*** ******* *****, ******, ** * 313-***-**** * ac0obt@r.postjobfree.com

An energetic, disciplined, versatile, and results driven 17-year Management/Engineering veteran with exceptional leadership, communication, problem solving, and relationship-management skills. Responsible for increase productivity, quality, and profitability through keen data analysis and process design. Excel at completing projects accurately, on time, and within budget. Proficient in AutoCad, Word, Excel, PowerPoint, Visio.

AREAS OF EXPERTISE

Lean Manufacturing Supply Chain Management Just-in-Time (JIT) 5S and Kaizen

Process Redesign Cost Reduction Project Management

PROFESSIONAL EXPERIENCE

CATERPILLAR (formerly Texas Power Systems), Seguin, TX 2013-Present

Commercial engine manufacturer

Manufacturing Engineer, Seguin, TX

Following and maintaining practices and systems in a manufacturing facility

Studied and evaluated process improvements in engine assembly. Ensured proper balance of workflow and maintained quality system controls to eliminate waste.

Selected Contributions:

Updated work instructions and tooling for engine assembly by using the Engineering Change Request (ECR) process.

Purchased tooling and equipment for current engine assembly and new engine assembly prototypes.

Improved assembly operation productivity and efficiency by overseeing a $3.5M capital project for the development and implementation of a new assembly line.

TEXAS POWER SYSTEMS, Seguin, TX 2011-2013

Commercial engine manufacturer

Industrial Engineer, Seguin, TX

Following and maintaining practices and systems in a manufacturing facility

Studied and evaluated job performance and efficiency in engine assembly and Hot Test areas. Engineered and implemented organizational line balances to ensure proper efficiency and plant productivity. Ensured proper balance of workflow and maintained quality system controls to eliminate non-value added processes.

Selected Contributions:

Performed comprehensive time studies in engine assembly and Hot Test areas.

Increased productivity by 40% from 12 JPH to 20 JPH by eliminating waste in the system and line balancing the work content.

Reduced the overall cost to the company by $700K a year by reducing the number of hourly personnel and eliminating one shift of operation using lean manufacturing principles.

GENERAL MOTORS CORPORATION, Buffalo, NY 1999-2011

World’s largest automaker

Senior Industrial Engineer, Buffalo, NY 2010-2011

Following and maintaining practices and systems in a manufacturing facility

Provide IE support for plant Skilled Trades groups which includes standardized work development, layout support, and improve utilization. Maintain master plant industrial engineering AutoCad layouts.

Selected Contributions:

Improved work place organization (5S) by developing standardized work for daily workplace organization for the machining department.

Developed and maintained a tracking sheet to capture Maximo workplace organization work orders for the machining department.

Worked with manufacturing to understand and update the machining department gage charts per GMS standards.

Created and updated plant layout changes.

Determined the indirect manpower requirements for the maintenance department supporting assembly and machining, analyzed and made recommendations to reduce the indirect manpower by use of maintenance work orders and equipment downtime.

Directed the development and implementation of a Crank Lab to measure cranks for a new launch product.

Production Supervisor, Buffalo, NY 2009-2010

Supervisor of hourly employees

Leads daily activities in executing the business plan for I4/5 Engine assembly line to meet production requirement and to maximize labor utilization. Drives performance culture through goal achievement for Safety, Quality, Responsiveness, and Cost through safe and effective utilization of materials and equipment. Promotes organizational culture of continuous improvement by championing the use of Lean Manufacturing principles.

Selected Contributions:

Motivated and lead a team of 30 plus hourly employees to successfully achieve business matrix goals in the areas of Safety (0 recordables/lost work days), Quality (92% first time quality), Responsiveness (100% build to plan), and Cost (0.75 HPU).

Assessed training levels of all employees in area of responsibility to ensure training effectiveness, depth of skills on critical processes, and cross training to maximize the flexibility of the workforce.

Senior Industrial Engineer, Buffalo, NY 2008-2009

Following and maintaining practices and systems in a manufacturing facility

Designed and implemented effective production processes. Performed time studies on production equipment to successfully establish production bottlenecks. Monitored equipment downtime and implemented corrective action procedures.

Selected Contributions:

Created and implemented efficiency enhancement to generate more than a 10% improvement in overall first time quality from 80% to 90% for the plant’s assembly manufacturing process.

Determined the bottleneck or constraint of the assembly process by using the data from Theory of Constraint and simulation models to create action items to improve or eliminate the bottleneck or constraint.

Ensured optimal equipment operation without costly downtime by establishing a preventive maintenance schedule.

Developed a process and system for batch run sizes to maintain proper work in process and minimize changeover times and product variations.

Production Supervisor, Livonia, MI 2007-2008

Supervisor of hourly employees

Provided leadership to hourly employees in all aspects of production. Reviewed and evaluated documentation to ensure that processes are performed according to quality and safety standards. Complied with terms of local and national labor agreements.

Selected Contributions:

Using team concept and lean manufacturing methods, led 7 employees with an average of 25 years of seniority to achieve and exceed all business matrix goals in safety, quality, responsiveness, and cost in the machining manufacturing process.

Assessed training levels of all employees in area of responsibility to ensure training effectiveness, depth of skills on critical processes, and cross training to maximize the flexibility of the workforce.

Industrial Engineer, Livonia, MI 1999-2007

Following and maintaining practices and systems in a manufacturing facility

Solved and improved people oriented issues by implementing standardized work processes, workplace organizational enhancement, and visual control mechanisms. Engineered and implemented organizational line balances to ensure proper efficiency and plant productivity. Contributed to the implementation of lean thinking techniques.

Selected Contributions:

Significantly reduced waste by eliminating 20% non-valued added time or $450K a year.

Lowered inventory costs by as much as 12% or $60K a year and optimize throughput by implementing Just-in-Time strategy.

Redesigned floor layout by reducing manpower by 5% or $300K a year to achieve the cost goal of 0.85 HPU.

Assisted in the design of a fixture to eliminate an ergonomic issue for handling parts.

Developed the direct and indirect manpower requirements for the assembly line, analyzed and made recommendations to reduce the direct and indirect manpower by use of process flow analysis, material flow, plant layout, and predetermined time data.

EDUCATION

MBA, Davenport University, Dearborn, MI 2003

Strategic Management

BS, Clemson University, Clemson, SC 1998

Industrial Engineering

MEMBERSHIPS / AFFILIATIONS

Livonia School District/ General Motors science program outreach volunteer

Midnight Golf Program, Mentor

Church Board of Trustees Member

Outstanding Young Man of America

National Society of Black Engineers (NSBE)

Institute of Industrial Engineering (IIE)

General Motors African Ancestry Network (GMAAN)

General Motors Professional Manager Network (PMN)

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