Manufacturing/Lean Manager

EDWARD J CHMELA

*** **. ******** **. *** Plaines, IL 60016

847-***-**** **********@***.***

PROFESSIONAL SUMMARY

Engineering professional with (17) years of manufacturing management and Lean implementation experience. Responsible for creation, implementation and adaptation of continuous improvement programs in multi-plant, multi-state operations. Improves quality, delivery and profitability through waste reduction, efficiency gains and maintaining an upbeat positive attitude with enough of a sense of humor to make the day enjoyable. My goal is to attain a challenging position allowing me to utilize my knowledge and management experience along with my track record of waste removal and cost avoidance to develop beneficial and sustainable operational changes.

PROFESSIONAL EXPERIENCE

December, 2015 – Present – Continuous Improvement

JOHN CRANE, Morton Grove, IL – Manufacturer of seals for the oil & gas industries ($1176MM)

Promoted to Continuous Improvement Manager

Implemented Lean Manufacturing practices including training, 5S and visual management. Held accountable to audits conducted by offsite global Lean reps

Developed process to verify that machining parameters meet tooling parameters and transfer that data to CAM software database

Revised and optimized new plant layout including machinery moves from other buildings

January, 2014 – September 2015 – PLANT MANAGER

PROTECTOSEAL, Bensenville, IL – Manufacturer of vapor and flame control equipment ($30MM)

Direct manage 60 union employees and a staff of 6

Responsible for production, purchasing, manufacturing engineering and facility management

Improved on-time delivery from 63% to 97%

Introduced Lean concepts to improve production

November, 2011 – February 2013 – MANUFACTURING ENGINEER

DEZURIK, Schaumburg, IL - Provider of specialty valves ($25MM/$180MM)

Developed manufacturing processes previously undefined

Developed tooling solutions to improve efficiency

Maintained compliance to EPA operational requirements

Responsible for maintaining functional routings during implementation of a new ERP system

August, 2008 – November, 2011

LEAN CONSULTING, Des Plaines, IL - Various companies in the Chicago area

Analyzed operation flows to develop Lean solution plan

Developed operational specific 6S programs

Developed operational specific Lean programs

Developed changes along with implementation plans

Provided Lean training and implementation presentations

Developed visual recording and displays of related metrics to chart improvements

October, 2005 – August, 2008 – LEAN MANUFACTURING MANAGER

SEIGLES/STOCK BUILDING SUPPLY, Elgin, IL - Provider of professional building materials and services ($400MM/$5.2B)

Created and initiated an event driven Lean Manufacturing program that utilized continuous improvement methods along with available resources to address current needs while creating a culture of change within each environment through leadership and employee empowerment

Responsible for developing an approach for each individual location GM that included Lean education, an implementation plan with milestones and expected improvements to current metrics

Worked with customers to develop the most cost effective solutions while maintaining the highest quality

Planed and facilitated Lean events: develop team objectives, scope, and roster; perform formal team training for particular event type; counsel team throughout event to ensure objectives are reached; drive follow-up process to ensure gain sustainability

Facilitated successful Lean events realizing typical gains of 20-25% and up

Heavy involvement with Safety, Quality, Delivery and Productivity issues

Developed and created time reducing operational devices that allowed for improvement in safety and/or time reduction

Relocated and reduced Millwork facility layout by creating flow product cells, resulting in a 60% reduction of floor space

August, 2002 – October, 2005 - MANUFACTURING MANAGER

MPL/RINN (A DIVISION OF DENTSPLY CORP), Elgin, IL - Provider of products for dental professionals ($47MM/2.2B)

Began as an Industrial Engineer, involved in Kaizen events to form cells and improve workflow. Responsibilities covered 3 companies within division

Cost justification, selection, purchase, validation and implementation of $500k in capital equipment

Promoted to manager of component department due to production bottleneck. Improved production over 60% while improving efficiency from 66% to 99%. Implemented Kanban system along with visual scheduling. 15 direct reports

Promoted to Manufacturing Manager. Responsibilities include Assembly department, component department, Maintenance/tool room and engineering support for remaining component departments. Improved efficiency from 62% to 78% in Assembly department. Involved with the implementation of visual scheduling and coordinated production between scheduling and other departments to better utilize resources. 40 direct reports

Responsible for estimation, creation and adherence to departmental budgets

Worked under FDA and ISO requirements

October, 2000 – December, 2001 - SENIOR MANUFACTURING ENGINEER/AREA MANAGER

TUTHILL CORP., Elk Grove, IL - Provider of machined products for large equipment manufacturers. ($27MM)

Participated in and led multiple Kaizen events pertaining to cellular improvement, cellular implementation, SMED and design improvements

Implemented production and scheduling boards to improve on-time delivery from 65% to 94%, while reducing backlog

Project leader in resolving major manufacturing problems at other companies within our division (New Haven, IN and Mendota Hts, MN)

Made production improvements in machining and assembly areas generating annual savings of over $50,000

Management of the Tool Room, Tool Crib, Tool Grinding and CNC area, consisting of (7) employees, were added to my responsibilities

Maintained ERP through SAP

May, 1998 – October, 2000 - MANUFACTURING ENGINEER/MAINTENANCE MANAGER

BODINE ELECTRIC COMPANY, Chicago, IL - Manufacturer of fractional horsepower electric motors, gearmotors, and system-matched motion controls. ($60MM)

Implemented cellular manufacturing, utilizing one-piece-flow technique, Kanban applications, set-up reduction and Kaizen events

Became lead engineer on capital equipment justifications & purchases in excess of $2,000,000

Responsible for bringing newly developed products into production

Revised processes to reduce manufacturing time thus increasing productivity and reducing cost

Management of the maintenance department, which contained (9) skilled mechanical, electrical and facilities people, was added to my responsibilities

Safety team leader including safety program management

Responsible for development of maintenance budget

December 1996 – May, 1998 - MANUFACTURING ENGINEER

MPC PRODUCTS, Niles, IL - Manufacturer of products for the aerospace industry ($125MM)

Responsible for all manufacturing vendor inquiries

Determined corrective action for discrepant incoming parts utilizing functionality, need and re-workability

Worked with CNC turning, CNC milling and E.D.M. on processing, quality and machining concerns along with fixturing and process changes to enhance production

Revised tool crib operation while working within current computer system

Given the responsibility of bringing a $500,000 Navy project to completion

August 1993 – December 1996 - MANUFACTURING ENGINEER/TOOL CRIB MANAGER

ACME INDUSTRIES, Des Plaines, IL - Manufacturer of medium to large precision products. ($37MM)

Developed routings, tool lists and process drawings in a CNC environment

Streamlined processes through the use of time studies & the implementation of new tooling, producing annual savings of over $100,000

Tool purchasing and organization, were added to my responsibilities which included over $600,000 in tooling purchases annually and supervision of tool crib employees

Developed a computerized bar code system to relate tooling costs to particular jobs

On a daily basis managed new projects and provided shop floor support

Interacted with quality control to develop & maintain manufacturing standards

Continued constant involvement with vendors to produce best value and managed system to keep optimum balance of on hand tooling

August 1992 – August 1993 - QUALITY/PRODUCTION ENGINEER

CAMCRAFT, Franklin Park, IL - Manufacturer of precision machined components ($60MM)

Worked with AutoCAD on revisions

Designed and implemented employee training program

Used SPC to identify and correct quality flaws

Traced and resolved actual production vs. quote discrepancies

EDUCATION

Bachelor of Science, May 1992, Northern Illinois University, Dekalb, IL

Major: Manufacturing Engineering

Heavy math background.

Advanced computer literacy

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