Engineering Engineer
Resume:
James H. Gerlach
Columbus, Ohio *****
*************@*****.***
Product/ Process/ Operations
Engineering Specialist
Dear HR/ Engineering team(s),
I bring 30+yrs as a highly- trusted and very accomplished Product, Process and MFG Engineering specialist. I competently evaluate and conceptualize any corrective intervention needed, equipment modifications and manage all process changes to maximize all available equipment assets, train the Production staff, assist and address Maintenance Operations and streamline outside vendor services.
My professional interpersonal management skills, ensures a level headed, competent and technically confident leader and/or trusted assistant that delivers continuous best-case scenarios.
I am always approachable, glad to assist the team in any endeavors and willing to listen to any technical request and/or delegate in personal issues in total confidence, conformance and compliance with Company and Corporate guidelines.
You can trust my 30+yrs of incredibly successful applications expertise to elevate efficiency, safety and expand operations. I will deliver creative and innovative equipment & process intervention that will expand abilities, promote exceptional flexibility and outstanding stability, into every facet of your operations portfolio. I restore the manufacturing “magic” of smooth operations, equipment reliability and predictable operations… eliminating bottlenecks & difficulties with innovation on a shoestring budget.
I can easily serve as competent Engineering liaison between Engineering, Sales, MFG and your valued customers in near any technical, mechanical or process science endeavors. IE: visionary process interpretation, conceptual development, root cause analysis, electronics & controls, electro/mechanicals, hydraulics, pneumatics, Power Physics- AC/DC & DC/DC energy conversion/ distribution, visual non-contact verification (camera), thermal dynamics & diagnostics, sensor design, hi-power switch gear, robotics automation, code and access security, induction bonding, metallurgy, plasma & laser science, chemistry, presses to 800K tons, injection molding, laminates, composites, material composition sciences, vendor sourcing/ verification (molds, forms and dies), pumps, vacuum systems, paints/ adhesives and coatings, specialized tooling design & prototype fabrication, dynamic fixturing, PCB manufacturing and nodal-circuit-analysis (bed of nails), self-contained field product testing & analysis systems.
Any shift/ hours, overtime, weekends, holidays, on location or abroad, as a Project Manager, a Multi-craft Project Engineer or master of prototype development… get it done, old-school Professional accountability… every associate, manager, owner and investor can expect and be proud of, PERIOD!
I am kindly requesting a personal interview to introduce myself to the Operations staff, review my enduring Engineering achievements and prove myself an “outstanding investment opportunity” to assist and serve beside the MFG professionals that support operations.
(Employment History): Expanded
(2013- 2016) Sandvik-Diamond Innovations (super abrasives) Worthington, Ohio 43085
Title: 2nd shift Maint. Engineer / Project Engineering Support
*Electrical/ mechanical/ electronic repairs and calibrations to heavy Hydraulics (780K+ tons) *ROOT cause analysis, modifications & fabrications of custom MFG Equip/instruments
* Greatly extended the DIE’s cycle life and increased the efficiency to all diamond press DIES by delivering AUTOMATED (geometric dimensioning and dynamic tolerancing) on-the-fly speed, accuracy and data acquisition w/pre-calculated mathematics and settable tolerances
* Normally, DIE measurements average 6hrs w/2-3 Carbide operators. It is also very dangerous to remove DIES from the presses and when flipping the DIE over to access both sides of the DIE cavity …I have developed an automated measurement instrument, allowing accurate recording of all measurements, INCLUDING ALL math calculations for deviations from parabolic, stretch, concentricity, abrading, compression, cold forming, surface hardness, puckering, buckling, pitting etc.… all required measurements and parameters from BOTH sides of the DIE in under 18 min. It now takes 1 person & calculates to well over $1,871,000/year - forever!
* I also re-designed and modified their DIE lapping equip/ instruments to perform automated operation of DIE maintenance & can take corrective actions, even alignment off-setting
* Fabricate all non-available components and rare parts as needed for plants MFG equipment
* I also developed and fabricated a successful PLATING system/ instruments to refine and expand on the process of depositing (gold/ Nickle/ Silver) onto the entire surface of the diamond in only 4hrs -vs- their original method, taking 64+hrs…used for the previous16yrs $$$
* I minimized handling, repetitive motion injuries & tripled output by; introducing robotics (ABB) and Siemens controllers w/additional automation into the dedicated MFG/assembly cells
* Simplification and adaptation of new equipment and simpler SOP’s, united the MFG team associates, willing employee participation rose from 23% to over 80% in only 12 weeks
* Design/Fab devises that use the waste air from the MFG equipment to power the collection device, designed to remove dangerous air-born debris… “DEBRIS-FREE AIR anywhere”
* Deliver on custom optical (dual-camera) ID & QC system for 100% inspection… now used in the precise placement and induction bonding of diamond tooling, a 300% increase in through-put
* Introduce advanced and more capable cameras, Robotics ABB, Siemens, HMI controllers, conveyors and diverters, into the dedicated but now “product-flexible” cell operations.
(2012-2013) Jefferson Industries /Tier-1 (HONDA) West Jefferson, Ohio (contract)
Title: 3rd shift Maintenance Engineering: Automotive Stamping/Welding/finishing
580+ welding robots, 300+ semi-automated assembly & welding fixtures, 400+ Test & data acquisition fixtures… in a continuously changing and aggressive automotive MFG environment.
* Teach welding Physics to the technical Maintenance staff and a few Engineers
* Using diagnostic tools for Temperature management, water cooling and thermal difficulties
* Teach hi-Power AC/DC and DC/DC power distribution, diagnostics and management
* Power transmission losses, weld penetration and metallurgic bonding sciences
* Train techs on Robotics accuracy, weld placement, and corrections to robot coordinates
* Teach diagnosing Weld Bond analysis & correcting w/power inverter adjustments
* NEW Model turn-over/ Remove existing equipment and robots & ready real estate for New
* TIG, MIG, Resistive, stick, wire, Optical analysis
(2012-2012) HAM Honda of America Marysville, Ohio (contract) 90days +
Title: Maintenance Engineering Robotic Paint/ Operations and control Systems
* Electronics, Technical and Mechanical Engineering support to MGF system, controls and maintenance to all Production Robots and system peripherals, plant wide.
* Maintain robots for perfect Paint delivery and finish QC, on the -fly color changes, Debris systems, Air filtration, drive systems, pneumatics, hydraulics, logic controllers and operator HMI systems
* Develop simple and cost-effective solutions $63 to eliminate the wear and breakage issues surrounding the guide tracks in the full body etch & prime “emersion tank” from weakening over time, breaking at the welds and dropping a full car body into the acids. HUGE savings…at least 1 car fell in every 2 months for many years. Each took a good 4hours with 5-10 techs and Engineers working to get back on line.
* Design & fab a dual-camera optical system to (Continuously) measure the parameters of every single chain link, in the 35 miles of pull chains and dogs that automate the plant. NO more dangerous measuring …the damaged links are now safely marked, easy to ID and quickly replaced, focusing human resources where needed. This also greatly reduced track hang-ups, damaged equip. and E- STOP issues.
(2010-2012) KoneCrane Intl. Springfield, Ohio (contract) Express Professionals
Title: ME Manufacturing Engineer & Project Engineer (International CRANE solutions)
* Provide organization and production / assembly guidance to MFG, Plant // absorbing the purchase of 7 crane competitors, each offering many options... MY mission was to devise a cost and time effective manufacturing process to manufacture, test and ship every single crane to anywhere in the world.
* Develop & deliver an impressive single line pull methodology to ELIMINATE assembly/ MFG cells, opting for a single line simplicity. Stock now encompasses the production floor with no more waiting
* Each employee has an ID and pulls a part in seconds-as-needed from both sides of the production line
* Design and implement overhead trolley system in tandem with a single in floor chain & dog system
* Incorporate digital bar codes and customer IDs’ to optimize pulls, eliminate human errors and practically eliminate part back-logs. Inventory tracking info- w/ who pulled each item in seconds
* Material pulls are reduced by 80%, making 46% of stocked and counted materials floor stock on movable carts that can be easily replenished in minutes, speeding production and easing tensions on stock
* I Automated the cable and power connections test station to perform full load diagnostics and voltage drop analysis on every connection of every cable assembly for 100% full equipment testing and verification w/data sheet printout for each customer and their customer’s files. NO more bad cables!
* The final KEY was for me to design and fabricate a test station with digital inverter loading controls, diagnostics & data acquisition. I repurposed & performed digital “magic” w/an old shipyard crane.
My New system design, performs automated diagnostics on every Customer crane purchase (s)… Voltage, phases, v-losses, current ratings, frequency, load stability, load/power diagnostics to catch the slightest imperfection in the control circuitry/sensors, electrical and sensor/ controls cables or gearbox… finding the tiniest of (micro-chips on the teeth of gears, fit and/or poor surface finish), flawed bearings and even detection of the slightest miss-matched phase windings in the motor. Data is taken through QC during the dead & static lifts sequences, PWR- diagnostics and energy/load verifications… All parameters are monitored, recorded and printed out for the customer and for the KoneCrane data archives.
SO MANY DOUBTERS, resulting in a couple of my proudest accomplishments & achievements!
The entire project came in under-time, under-budget and performed better than I could have imagined.
If your company requires a dynamic Engineering Professional of my caliber to bring continuous visionary level SOLUTIONS, creative operations intervention and/or trusted Personnel Management to deliver your dreams and visions of success, please contact me…I will make-it-so! 614-***-****
Best Regards, James H. Gerlach (DOC)
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