Engineer Mechanical

ALBERT MAGNUSZEWSKI PEng.

*** *** ********* ******, ********, ON, N2K 4L8

Toronto, M5R 2R5

Cell: 226-***-**** ******@*********.**

Experienced Mechanical Engineer in Automotive Automation Processes, Parts Manufacturing and Projects Management, Launching new Programs, Building and Commissioning of Production Lines, Mechanical Design, Drafting, R&D, Engineering Management.

TECHNICAL SKILLS

•APQP •PFMEA •DFEMA •8D •5S •6-Sigma •OEE •AD&T• Design of Assembly and Manufacturing Processes •Process Flow •Floor Layout •Continues Improvement •SPC • Building Assembly Lines •Machines Design •Jigs Design • Fixtures Design •Gauges Design •Tooling Design • CNC Machining •Precision Grinding • Design of Lift Assist Devices •PSHSR •PLC Programming •Pneumatics •Hydraulics • Optical Measurements •Robotics • Light Curtains •CMM •Forging •Forming •Bending •Stamping • Deburring •Plating •Painting •Plasma cutting •Welding• Boilers and Pressure Vessels Design and Manufacturing •Instrumentation and Data Collection • Materials Failures Analysis • Root Cause Analysis •Metallurgy •Injection Molding •Casting • Heat treatment Processes •Induction Hardening •Springs Design and Manufacturing •Valves and Regulators Design and Manufacturing •Piping Design •Pumps Manufacturing and Assembly •Automation • AutoCAD •Solid Works •Inventor •StaadPro •Mathcad •DaisyLab(Labview) •Mnitab •Autopipe • DesignCalcs • Solid Edge •Catia •Microsoft Office •Microsoft Project •FEA Modeling •ANSYS •Cosmos •Inventor Simulation

PROFESSIONAL EXPERIENCE

HONDA MANUFACTURING CANADA, Alliston Mar 2018- Current

Process / Industrial Engineer Contract expires June 01/2018

• Time studies, improvement of assembly and welding processes for SUV CRV manufacturing lines

• Robotics, conveyors, transfer drives, handling equipment, automation, infrastructure, testing

STACKPOLE INTERMATIONAL Global Automation Group, Ancaster Sept. 2017-Feb 2018

Process Engineer

• Designed Automation Processes for Assembly Lines for Ford and GM Programs.

• Preparing FMEA, Process Flow

• Building and commissioning of automation lines which included robotics, palletized conveyors, servo drives, assembly stations, pressing and torqueing operations, precision LVDT measurements, vision systems, robotics, gauging stations, laser etching, scanners, data collection

• Improved assembly and Manufacturing processes

• Wrote process sequences for creating PLC programs

•Revised and approved Design Concepts of Machines

•Recommended Servo Control Systems, Robotics, Vision Systems, Safety Control Devices,

• Calculated formulas for multiprobe gauges, collected and evaluated data for Keyence Multipoint Measurement gauges

• Conducted Gauge studies in accordance to AIAG Manuals Using Minitab

• Failure Mode Analysis for existing Assembly Lines and Processes Improvement

• Conducted study and runoff of Assembly Machines

• Solved Problems

• Used Cad Software AutoCad, Solid Works

ATLAS FLUIDS ( MARTINREA), Brampton Apr 2017 –Aug 2017

Senior Process Engineer Permanent

• Process design for GM Program 65T and 45T: cutting, forming, bending, welding, brazing,

machining, torqueing leak testing, assembly, automation

• RFQs

• Commissioning of equipment

• Prototyping

• Balancing Lines

• Process Improvement

• APQP

• Fixtures Design

• Material flow

• Floor Plan

QUALTECH, London, On June 2016 to Apr 2017

Manufacturing Engineer Contract

• Leading Installation of new assembly lines for back seats for 2017 GM Ingersoll Program

Preparing of Floor Plan

Relocation of Prototype Lines

Preparing infrastructure: electrical, ventilation, water, compressed air systems

Conducting PSHSR

Preparing JES, Value Map, FEMA

Optimizing Lines

Product Development

Design and Commissioning of Handling Systems and Fixtures

Commissioning of Conveyors and Fixtures

• Programming Optical Keyence cameras

Programming Torque Controllers

Supervising integration of MES with MRP and PLC programming

Supervising IT integration

Prepared Timelines and coordinated schedule between contractors, maintenance and engineering

Continues Improvement

Production support

FAURECIA EMISSIONS CONTROL SYSTEMS, Brampton, On March 2015 to Feb 2016

Program Manufacturing Leader for Chrysler Program Contract

• Led Manufacturing Program of vehicle exhaust systems for Chrysler 2017 Models

• Prepared CAR and RFQ

• Led team of Engineers and Contractors in design and installation

of automation, modification of machines, cranes and lift assist devices for Chrysler Production

lines (Robotics, PLC programing, Pneumatics, Structural, Prestart Health

and Safety Review OH&S 851

• DFEMA, PFEMA, APQP, PPAP, Process Flow, 8-D, Process Improvement

• Reduced Tact Time

• Used software: SolidWorks, AutoCAD, MS Project, MS Office

• Exposure to Welding, Assembly, Fixtures and Tooling Design, Advanced Dimensioning and Tolerancing

ASME Y15.5,Y14.43, Welding, Forming, Material Handling BTH-1, B30.20,

Leak Testing, Automated Measurements, Robotics, Safety Light Curtains, Pneumatics,

• Auditing vendors in USA and Canada.

CLEAVER-BROOKS, Jan 2013 to Jan 2015

Engineering Manager Contract

• Planned, Motivated, Directed and Controlled Engineering Department 12 reports

• Hired, Trained and Mentored Engineers and Technical staff

• Calculated and Designed Boilers and Pressure Vessels using softwares: DesignCalcs, Compress, Inventor Simulation, Mathcad, Bentley Pressure Vessels, Autopipe and Autopipe Nozzle, Autocad, Inventor and Inventor Simulation

• Preparing Welding processes WPS, PQR using ProWrite

• Calculated structural stresses using Bentley StaadPro

• Calculated platforms for Live Load, Dead Load, Seismic and Wind in accordance to ASCE-7-10 Code

• Checked Drawings, Calculations and Sealed Documents

• Applied Boiler and Pressure Vessel Code Section I, II, IV, VIII and IX.

• Calculated and selected Pumps and Valves ( Grundfoss, Goulds, Fisher, Flow-Serve)

• Designed Piping in accordance to B31.1 Code ( Pipe-Flow)

• Managed Project using Microsoft Project

• Led Corrective Actions and Solving Problems

• Cooperated with Materials and Production Departments

• Preparing and Submittal of documentation for vessels registration Canada-wide

• Implemented of new technologies ( robotics welding )

• Prepared Budget and Department reports

• Tracked Engineering Department Performance

• Organized Trainings for employees

• Represented Company on project management meetings with customers and vendors.

• Checked and Sealed drawings and calculations

• Improved Processes

• Standardized Products

ABERGER PRECISION, Brampton, On Apr 2011 to Dec 2013

Manufacturing/Industrial Engineer Contract

• Managed projects

• Evaluated new automation systems

• Conducted bidding for automation companies and prepared technical specifications for new automation

systems which incorporated optical vision systems, vibratory feeding systems, robotic systems, on line

precision measurements and data collection

• Involved in Advanced Quality Planning Processes

• Preparing FEMAs, Process Flows, Machine Layouts, Packaging Instructions

• Achieved significant Improvements of processes

• Prepared SH&ED programs

• Prepared Value Stream Mapping to balance Production Lines

• Designed Experiments DOE to identify problems and solve them

• Analyzed Production efficiency and Identified constrains

• Made recommendations for purchasing new equipment and machines, RFQ, bidding, attended in installation,

and commissioning of new equipment

• Audited Tool Suppliers and tool coating processing plants

• Made Metallurgical analysis and audited heat treatment plants in Canada and USA (Nitrex, Bodycote, Blue

Water, Grand Rapid Heat Treatment Processing)

• Improved raw material aluminum bar processing technology with cooperation with Alcoa Corporation, USA

• Led corrective actions and 8-D's

• Prepared FMEAs, 5S plans, Process Flows, Packaging and work instructions

• Implementation of newest technological achievements in tool design and process design.

• Involved in troubleshooting and upgrading precision multistage measurements gauging systems

• Tested Air gages, Laser gages, Eddy Current gauges

• Tested optical systems: Keyence, Cognex, Omron.

• Tested integration of optical systems with robotic systems

• Tested Feeding Systems

• Cooperated with oil supplying companies in selection and testing cutting oils.

• Calculated and selected centrifuge central cleaning system for the plant

• Designed of cutting oil cooling system with implementation of water cooling tower, heat exchangers and piping system

• Contributed to increase machine up-time

• Used software: Excel, Word, Power Point, Minitab, Ms Project, Catia v20, Autocad

• Participated in SPC data collection and conducted data analysis using MiniTab

• Analyzed processes for manufacturability

• Participated in Quality audits and Corrective actions

• Introduced new measurements technologies to production environment

• Prepared presentations for management

• Procured reports

GFI CONTROL SYSTEMS, Kitchener 2006 to 2011

Mechanical Engineer/Product Engineer Contract

• Developed heavy duty Regulators for Natural Gas for Daimler, Bosch, Volvo, Woodword, Advantek,

Volkswagen, Input 350 bar, output 6-17 bar

• Developed tank valves for Honda, Toyota, Hyundai, Dynatek, BAF, Lincoln for natural gas and hydrogen

for the pressures up to 450 bar.

• Designed using AutoCAD, Solid Edge, Solid Works

• Applied Standards ASME Y14.5-2009, NGV 3.1, ECE 110, ISO 15500, CGA S-1.1-1994 Pressure Relief

Device Standards Part 1-Cylinders for Compressed Gasses, and ASME Sec VIII Code.

• Implemented Spring design ( Spring Design Software)

• Build Prototypes

• Prepared Product Failure Mode Analysis

• Prepared FEA Modeling (Ansys 11, Femap9.3.1, Cosmos)

• Tested leakages

• Made experimental Vibration, noise, thermal, pressure and fatigue tests

• Calculated flow factor Cv and took bench characteristics.

• Prepared Product validation (Validation Plan, DFEMA, Control Plan, 8-D's)

• Conducted Laboratory tests with hands-on

• Developed processes for machining, forging, injection molding (Stainless Steel, Color metals, Plastics),

plating, anodizing (brass, aluminum)

• Calculated sealed connections ( Parker, Diacom)

• Programmed Omron PLCs

• Install instrumentation for measurements of pressure, temperature, acceleration, torque, displacement and force.

• Tested electronic components and circuits using oscilloscopes

• Tested valves and regulators using pressurized nitrogen gas at pressure up to 9000 psi and tested

hydrostatically valves up to 23 000 psi,

• Wrote reports

• Led the biggest corrective action involved approx 200 personnel and 6000 vehicles and 42 000 regulators

• Customer's support

GUELPH TOOL AND DIE INC.

Process Engineer 2004-2005

Engineering supervision over plant Permanent

Parts Stamping, Forming, Bending

Lean Manufacturing, Kaizen, 6 Sigma, 5 S, 8-D,

Production Cost Analysis

Plant layout, Process flow, APQP

Cost savings and Problems solving

Time studies and Process efficiency improvement

Mechanical design (AutoCAD, Mechanical Desktop 3D Modeling)

Jigs, Fixtures, Tooling Design

Automation design

Hydraulics and pneumatics,

PLCs, CNC

Tubing and Rods bending progressive systems

Robotic welding

Prepared Parts Assembly Instruction

Launching new products

Corrective Actions

Maintenance and Quality support

LINAMAR CORPORATION, Guelph, On 1995 to 2003

Manufacturing/Project Engineer Permanent

• Engineering supervision over departments: Manufacturing, CNC, Sheet Metal, Fabrication, Raw Material,

Paint lines, and Assembly (Skyjack)

• Managed new Projects ( Hastech), Launched 5 projects in three weeks

• Mantained good relationships wth Customers and Vendors,

• Procured and negotiated contracts with contractors and vendors

• Designed hydraulics, pneumatics systems

• Applied Lean Manufacturing

• Prepared Plants Layout

• Represented management in the Plant Health and Safety Committee

• Prepared Standard Cost Analysis

•Prepared Process Specifications, FMEAs, Process Flows, Control Plans, Customer Focus Plans, 8D, 5S, APQP

• Achieved multimillion dollars Cost savings by implementing shafts with forged splines in Ford transmissions

• Improved processes and reduced cycle times

• Contracts preparations

• Created 900 routings in 3 weeks for fabrication shop and stored in MRP system

• Programmed CNCs

• Designed Machines, Automation and Handling systems

• Designed and supervised Induction hardening and Tempering Processes

• Evaluated Failures of parts and conducted Metallurgical Microstructure Analyses

• Designed and developed parts for FORD, CHRYSLER, GM, SANDEN, Delphi, Mascotech, Delphi, Nicherin,

• Assembled Pumps for Detroit Diesel

• Set up machines

• Designed Fixtures, gauges and tooling

• Auto-CAD, Solid Works, Turbo-CAT, Master CAM, MS-Project, Excel, Word, Power Point

EDUCATION

Technical University of Lodz, Lodz, Poland, MSc Mechanical Engineer- Department of Applied Mechanics

Thesis: “Applying Laser’s Holography Method for Vibration analysis of Plate Structure”

Technological University of Warsaw, Warsaw, Poland, HVAC,Post Graduate Study – Department of Sanitary and Water Engineering, Thesis: “Heating Pumps”

Conestoga College, Guelph, On, Project Management

Conestoga College, Guelph, On, Quality Assurance

Conestoga College, Kitchener, On, Control Systems for Industrial Mechanics (Mechatronics)

Coestoga College, Kitchener, On, Robotics

Conestoga College, Guelph, CNC Programming

McNylor, Cambridge, On, CAD Operator

TRAININGS

Kaizen, FEA Modelling, Ferro, CMM Measurements, ASME Pressure Vessels and Boilers Code,

Bentley Learning Academy StaadPro, Autopipe, Autopipe Vessel, Prowrite, Autocad Inventor Simulation, Mathcad, Compress, Cognex Optical Systems Training, Sandvik Tool Academy Training, Borg Worner DOE training, TUV Root Cause Analysis, Geometrical Dimensioning and Tolerancing, Health, Safety and the law, Workplace Inspection Training Accident/Incident Investigation Training, Hazard Recognition and Control Standard First Aid and CPR, Painting – SICO, Metallurgy, Induction Hardening, Residual Stress, Fundamentals, Measurement and Implications Advanced Stress Analysis, Error Proofing, Failure Mode and Effect Analysis, Root Cause Analysis - 8d; Gleason Gear Cutting program, CAD/CAM, BULZER Coatings, Omron PLCs C Series Programming; Electro-Mechanical Measurements Instrumentation; FESTO Mechatronics (Pneumatics and Hydraulics).

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