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Quality/Process Engineer - Textiles

Location:
Bybee, Tennessee, 37713, United States
Salary:
85000
Posted:
February 07, 2018

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Resume:

Jim Harris

Cell: 615-***-**** Email: ac4dzl@r.postjobfree.com LinkedIn.com/jharris611

Experience Independent Consultant May 2013 - Present

Provide design, process and quality expertise to companies adding nonwoven technology to their product line.

Reemay, Inc. / Fiberweb Old Hickory, TN March 2007 – May 2013 Process Engineer / Quality Engineer

Process & Quality Engineer for Typar® & Reemay production and converting lines.

Directed all quality functions for all Typar construction products.

Managed ICC & CMCC certification process for construction products. Included set- ting up external auditor (RADCO) to meet quarterly external auditing requirements. Established cradle to grave traceability of construction products. Set up external testing of product to verify validity of internal lab data. Reported weekly to Sales Management Team on health of products being produced and roll out of product changes requested by Sales.

Certified internal ISO auditor.

External ISO auditor for PP additive vendors.

Analyzed quality lab data on Typar products (3 yr & 5 yr) and, using MiniTab statisti- cal analysis, established new targets, UL and LL.

Served as quality liaison for Typar automotive and geotextile product lines.

Managed vision inspection (ISRA) systems for Reemay production lines. Included upgrading central computers, writing recipes, defect verification on converting lines and training personnel on use of systems.

Coordinated with other Consolidation Team members to merge Madison operations into the Old Hickory site.

Conducted trials for R&D while serving as Quality / Process Engineer, including new products and improvements on existing products.

Member of Stage Gate Team monitoring commissioning of new R&D lab line and fa- cility.

Used various Lean Six Sigma tools (FMEA, Gage R&R, DOE, 5 WHY, etc.) as needed to solve complex Process/Quality issues.

Conducted statistical analysis of all current product data.

Obtained and maintained code certifications for all Typar construction products, with no deficiencies in 18 months.

Conducted capability evaluations for all Typar products.

Coordinated independent lab testing for product integrity reviews.

Wrote recipes, upgraded computer hardware and software, and oversaw the vision inspection (ISRA) reports. Coordinated to have ISRA experts teach fellow staff members on the program.

Improved converting efficiency and reliability for product lines, including flexo and digital printing.

Directed trial runs on PP production lines for R&D department. Western Nonwovens, Inc. Oakland, CA January 2005 – July 2005 Operations Manager

Managed all phases of Performance Insulation Division’s relocation from Oakland to Clinton, TN.

Completed site selection process in 2 months, including tax, wage, lease, and workforce evaluation.

Jim Harris

Reverse engineered critical process equipment within 3 months.

Negotiated domestic freight rates, saving $185,000 annually. BBA Nonwovens / Reemay, Inc. Old Hickory, TN Nov 2001 – January 2005 Senior Engineer

Provided technical assistance and process troubleshooting to polypropylene spunbonded lines.

Handled project engineering duties in modernizing outdated custom-built equipment.

Determined cause of draw roll motor seal failures on Typar lines using Process Mapping, C&E, FMEA, Gage R&R, and DOE (Six Sigma tools). Corrective action saved over $450,000 annually.

Developed new manufacturing model for Tycon converting operations using Value Stream Map (Lean Tool), thereby increasing productivity by 200%.

Assessed needs and requirements for implementation of new manufacturing software.

Developed process conditions necessary to transfer products from lower output line to wider, higher output line, resulting in 25% reduction in product costs.

Developed higher denier spunbond wick drain product to meet ROI requirements necessary to remain in market.

Determined cause of vendor defects in new generation of Typar Housewrap, reducing scrap levels from more than 35% to less than 5%, saving over $3M.

Utilized Six Sigma tools to achieve higher levels of recycle with improved yields - a 20% increase.

Samuel Strapping Systems Winchester, TN June 1998 – October 2001 Plant Manager

Supervised manufacturing plant activities of personnel, production, maintenance, and quality while communicating with customers and negotiating contracts with Steelworkers’ bargaining unit.

Directed $2.5M project to modernize 5 profile extrusion lines. Completed 18 month project in 7 months to meet company objectives. Three lines provided output of 5 older lines. Directed design, build, and installation of project.

Reduced conversion costs by 38% by restructuring plant and outsourcing non-core business.

Assisted sales by calling on high profile customers such as Smurfit-Stone and Tyson Foods to solve technical and quality issues.

Developed a closure plan for the Winchester plant, with projected savings of $2.5M per year. Plan was adopted.

Filter Specialists, Inc. Soddy Daisy, TN June 1993 – June 1998 General Manager

Assumed responsibility for Indiana operations with four-month order backlog and low manufacturing efficiencies. Developed and implemented a turnaround plan which saw the shipping of 85% of orders within 24 hours of receipt as well as the shipping of special orders within 2 weeks.

Expanded Tennessee operations with a $3.5M addition – which included installation of new extrusion technology which allowed company to become vertically integrated from resin to finished filter, and reduced finished goods’ costs by 34%. Acted as Project Engineer and Project Manager.

Jim Harris

Directed ISO certification process for Soddy-Daisy plant, earning certification in April 1998.

Called on high profile customers such as Ford Motor, Dow, Westinghouse’s Nuclear Services Division, and Nissan to roll out new fiber and filter products and assisted sales team in resolving technical and quality issues.

Developed new ultrasonic welding technique. Patent awarded. Plant Manager October 1990 – June 1993

Developed maintenance program resulting in 50% increase in machine up time.

300% productivity increase by implementing visual tools, incentive program, equipment changes, production scheduling overhaul and employee accountability – eliminating muda.

Directed growth of plant from 17 employees to over 125.

Completed $250,000 facility addition, adding 22,500 square feet to the facility and added a regional warehouse as well as a sewing and screen printing operation.

Held position concurrently with R & D responsibilities. Research and Development Manager June 1990 – October 1993

Staff level position reporting to the President.

Developed four new melt blown product lines, which were quantum leaps in technology.

Created a melt blown/spunbond/felt filter bag to meet critical DOW requirements for a new silicone product.

Developed a seamless melt blown filter bag.

Training

&

Certifications

Education University of Tennessee Chattanooga

Completed credits towards MBA.

Georgia Institute of Technology

Bachelors of Science in Textiles

• Cleaver Brooks Boiler School

• John D. Hollingsworth on Wheels, Inc.,

Carding Maintenance School

• Kepner Tregoe Problem Solving and

Decision Making

• Lean Manufacturing Certificate

• Licensed Infrared Thermographer

• Series Seven Security License

• FAA Licensed Private Pilot

Six Sigma Black Belt



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