Manufacturing Process Engineer

DONALD E. MATTHEWS

Senior Process Engineer Six Sigma Black Belt – ASQ Certification

*** ****** ******, **** *********, OH 43920 608-***-**** ***************@****.***

Summary of Qualifications

Developed manufacturing solutions to improve processes and quality. Utilized Six Sigma Black Belt and Lean Methodology in concert with team leadership and skills to problem solve, improve processes and reduce costs. Designed, programmed and implemented new manufacturing technology.

Experience

Senior Process Engineer 2014 - 2017

Bemis Company - Labels Division, Akron, Ohio

Led many teams for WCOM and continuous process improvement

Developed Six Sigma projects and 5S Kaizen events to improve processes and quality

Reduced printing errors with automated system for error detection and flagging

Championed improvements to presses with frequent interaction of press operators

Developed, programmed and implemented SCADA monitoring system for presses

Investigated and implemented new technologies and capital equipment purchases

Developed system for quality inspection of printing gears

Manufacturing Process Engineer 2012 - 2013

MAC Trailer Manufacturing, Salem, Ohio

Automation of workstations with capital equipment to reduce labor intensive processes

TAKT Time System development and installation, with Andon Signal Light System resulting in 50% increase in assembly line throughput

Coordinated training and projects for Lean Manufacturing & Continuous Improvement

Modification of plant layout and workstations to increase throughput (using AutoCAD)

Process Engineer 1993 - 2012

Stoughton Trailers, LLC, Stoughton, Wisconsin

Six Sigma and SPC project leader. Six Sigma / Lean tools used included Root Cause Analysis, Value Stream Mapping, Pareto Charts, FMEA (Failure Mode and Effects Analysis), Regression Analysis, SPC Control Charts, T-tests, Financial Audit, etc. Project examples include process improvement for automated axle nut torqueing to reduce variation (cost reduction over $100,000 per year)

Developed new manufacturing processes

Implemented SPC measurements and corrective actions for critical processes.

Developed system of network data collection for factory machines, including PC’s, PLC’s, touch screens, and bar coding (cost savings of $190,000 per year)

Designed, programmed, and implemented automated injection system using Think & Do PC Control and SCADA software (cost savings of $95,000 per year)

Managed project teams to specify and purchase custom built hydraulic and DC electric torque machines. (cost reduction of $150,000 per year)

Developed electrical one-line diagrams of entire plants for NFPA-70E Arc Flash Hazard Analysis and compliance, using SKM Power Tools EE Software.

Negotiated and managed energy contracts (cost savings of $275,000 per year)

Coordinated all projects for environmental compliance for over two years

Donald E. Matthews 608-***-**** ***************@****.***

Additional Related Experience

Systems Engineer and Manufacturing Engineering

LENNOX INDUSTRIES - Columbus, Ohio (facility closed in 1993)

Education

UNIVERSITY OF AKRON - Bachelor of Science Degree in Natural Science

Course work included: Chemical Engineering (2 years), Chemistry (3 years)

UNIVERSITY OF WISCONSIN, PLATTEVILLE

Electrical Engineering Courses, for pursuing 2nd Bachelor’s Degree

Professional Training and Skills

Six Sigma Black Belt – ASQ Certification. Minitab Statistical Software, Quality Improvement Workshops, Lean Manufacturing Methods, 5S Kaizen Blitz Workshop, Problem Solving Skills and Methods, AutoCAD and Co-create CAD software, SKM Power Tools Electrical Eng. Software, Think & Do PC Control and SCADA Software, Simulation of Continuous Systems (at Case Western Reserve University), Participative Management Skills and Team Leading, Mitsubishi PLC Programming, Siemens PLC Programming, Allen-Bradley SLC-500 Programmable Controllers, C Language Programming (at Microsoft in Chicago), Power Quality Analysis (Cutler-Hammer)

Memberships and Professional Development

ASQ (American Society for Quality) Member

IEEE (institute of Electrical and Electronic Engineers) Member

Past Chairman of Society of Manufacturing Engineers (Madison Chapter 75)

Taught informal classes on “Fundamentals of Manufacturing”

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