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Engineer Continuous Improvement

Simpsonville, Kentucky, 40067, United States
80,000+ per year
November 28, 2017

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Resume of John W. Falconer


HOME: *** *** ********* ****

Simpsonville, KY 40067

Cell: 502-***-**** Land: 502-***-****


To find an Industrial, Manufacturing, or Process Engineering position that will build and strengthen my abilities and background as well as let me apply my current knowledge and experience to the position for the company’s benefit. NO QUALITY ENGINEERING POSITIONS. I am looking locally, I am not able to relocate.


Inoac Springfield, KY 2016 – 2017

Process Engineer

Supervisor to 5 Process Tech who primary responsibility is to keep the production line and associated lines running. This includes supporting the computer operations in injection molding (not supporting injection molding)

Write the PM for the Process Tech to follow and make sure the PM’s are completed in a weekly, monthly, 6 monthly manner

Keep the camera system that inspects all final products running and verify through the running of red rabbits that the camera is working properly.

Maintain the torque guns are working properly and if necessary program the controllers to communicate with the network to validate all torques have been completed. Also program the controllers according to the spec of the product that the torques are being torqued correctly.

Address all quality concerns that come from the quality department and provide evidence that if an issue is ligament or not.

Supporting the Continuous Improvement Team on major continuous improvement projects as well as Kaizens projects

Preforming Monthly Continuous projects with in the production area and presenting the results on a monthly basis.

Writing job descriptions for the production area for production to follow

Writing work instructions for Process Techs, Production Supervisors, Team Leads, and Group Leaders to follow.

Autoneum Jeffersonville, IN 2014 – 2015

Process Engineer

Travel to vendors facilities for final inspection of machines prior to being shipped

Keeping track of all arriving machines and supplies to the factory from the vendors

Working with the techs from the vendors in the assembling of their machines

Organizing any additional resources needed in the assembly and placement of the machines (cranes, forklifts, etc.)

Working with local contractors to support the vendor’s techs in additional work needed for their machines to be finished and ready for production

Working with Autoneum’s development team in setting up the production floor for locations of the incoming machines from the vendor’s

Developing a consumable’s list of materials list needed for the machines once production begins

Working with the development team to have the machine make a viable WIP product needed for making the final product.

Updating the designs of the outer walls for the RUS machine to protect it from the environment.

Johnson Control Shelbyville, KY 2010 – 2014

Quality Engineer

Verifying that production is meeting the quality requirements that the OEM requires for the final product

Addressing all Quality concerns that the OEM customer has with the final product

Addressing all warranty claims that the OEM customer has with the final product

Addressing all quality issues that arrive at Johnson Controls from the vendors

Investigate all internal quality issues with the use of A3 format, Kepner-Tregoe, or DMAIC

Johnson Controls Shelbyville, KY 2010 – 2014

Quality Engineer (Con’t)

Audit PFMEA’s and Control Plans verifying the latest changes are recorded

Performing Quality audits in production, verifying the process that is written is being followed by production

Working with 3rd Party sort companies on sorting product that arrive from the vendor that do not meet quality standards set by Johnson Control.

Managing the Quality Techs to ensure Quality and production processes are audited daily

Working on Continuous Projects with the Continuous Project coordinator and manufacturing engineering

Updating the Element Instruction Sheets that supplement the work instructions that production uses for building the final product.

Johnson Controls Shelbyville, KY 2010

Manufacturing Engineer (Contract Position)

Create new work instructions for production for the new product Model

Create Element Instructions Sheets (EIS) for production for the new product Model

Stant Manufacturing Pine Bluff, AR 2005 – 2009

Manufacturing Engineer

Piloting potentially new fuel caps for potentially OEM and aftermarket production.

Verifying current production cells are capable of taking piloted fuel caps and turning the fuel caps into OEM and aftermarket fuel caps.

Working with design engineers and machine development for any necessary machine changes to production cells to produce new OEM and aftermarket fuel caps

Conducting capability studies on failed pilots to find what caused the failures and working with the design engineer to correct the fault to produce a future capable fuel cap.

Updating and producing new PFMEA’s on current and new fuel caps using the Ford Motor Company’s format for PFMEA’s.

Updating programs and installing new programs for covers that are to be lasered by the Rofin – Basaal Laser.

Taking designs drawn in AutoCadd and converting them into programs for the Rofin-Basaal Laser.

Maintaining current pad print operations are capable for current fuel caps.

Verifying and engineering the means to pad print new fuel caps.

Maintaining and if necessary, make changes to Uson vector tester programs for various pressure and vacuum leaks preformed on fuel caps.

Using continuous improvement and lean activities to improve production cell production and reduce scrap and wasted activity and improve OEE.

Updating floor layouts when production cells are moved to new areas in the factory using AutoCadd.

Updating the Preventive Maintenance sheets plant wide and insuring preventive maintenance is being performed on the production cells assigned to me.

Filling out capacity studies for General Motors using the standard General Motors capacity studies forms.

Dana Corporation – Commercial Vehicle Systems Division Henderson, KY 2005

Industrial Engineer III

Investigating and researching the use of robots to automate select positions on the assembly lines to reduce the cost of production.

Working with quality control in implementing quality issues on the suspension line to reduce rework of finished truck axles for Dana’s customers and reduce the cost of rework to Dana.

Working with Dana’s customers to find better ways to improve shipping quality.

Investigating, researching, and testing tools and product for better ways to improve the leak test done on axles and reduce the cost of the leak test material

Training the production workers on how to use the quality controls implemented.

Doing traditional time studies to update the standard times for the production lines.

Working on various continuous improvement projects for production lines that I was assigned to.

Helping implement lean activities for controlling and reducing inventory.

Investigating, researching, and working with corporate, testing Mylar tags to replace the metal id tags used in identifying axles for commercial trucks.

Hitachi Automotive Products USA Harrodsburg, KY 2002 – 2005

Industrial Engineer

Champion for the company in the use of Ford’s and General Motor’s ideas and theories in OEE (Overall Equipment Effectiveness) and TPM (Total Production Maintenance) and it application plant wide.

Using Excel and Visual Basic in creating, monitoring, and the changing application of a Production program based on OEE and TPM that will allow supervisors to input their production data and create a daily report for each shift.

Training supervisors, lead people, and anyone who would be using the Production program to enter in information and those would be using the Production program to pull information out for other reports.

Using Excel and Visual Basic in creating, monitoring, and the changing application of Monitoring programs based on OEE and TPM that provide up to the end of the shift information as well as create a monthly and budget period reports used by the Plant President and other high ranking positions to keep pace with the information from the Production programs.

Using Access and Excel in monitoring and maintaining a weekly Headcount Report and biannual Budget Report.

Using Access for updating and monitoring a data base for all in house models and pass through models that the company handles.

Using Excel to develop other computer programs that supervisors and other industrial engineers request to keep track of information their departments and sections.

Maintaining production lines that go from being a major line in the plant to a service line.

Developing production lines that are based on pass through products that come from Japan and go on to Hitachi customers.

Doing Time Studies to verify the current Standard Time’s for production lines that become service lines and for production lines that are set up for addition inspection of the major production lines final products.

American Printing House for the Blind Louisville, KY. 1999 – 2001

Co-op Operations Engineer

Updating and creating Bills of Material/Routings for Talking Books, Large Type Books, and Braille Books using Impact.

Doing Time Studies to verify current standards using Stopwatch techniques and Excel.

Updating Operation Descriptions for operations done in Tape Duplication using Word and Visio.

Floor Plan redesign for the maximum space utilization of Work Centers.

Create Visual Flow Displays to show the flow of material and products from Work Center to Work Center using Visio.


University of Louisville Bachelor of Science in Industrial Engineering

Bachelor of Science in Mathematics and Physics.


Microsoft Office

Visual Basic


Microsoft access

Microsoft Visio

MVP Plant


DFMEA, PFMEA, and Control Plan training by the Ford Motor Company

Uson vector training and programming.

Certified Kepner-Tregoe Practitioner

Desoutter Torque gun controllers

MVP Plant PM creating and updating

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