Manufacturing Engineer Lean

Alex Plavnik

**** ********* *****

Owens Cross Roads, AL 35763

H. 256-***-****

Cell 256-***-****

E-Mail: ***********@*********.***

Objective: A Mechanical Engineering position applying proven skills in engineering, teamwork, and task accomplishment. Solid work ethic fosters high productivity, quality results, and a solid contribution toward company profitability.

Experience: Over 20 years of experience in Mechanical and Application engineering with emphasis in Manufacturing process, CNC Machining, Technical specification, Supplier evaluation,

Machine Cutting Tool, Research and Development, Production Management, Product Management, Process Development and Quality Control.

Proficient knowledge of AQP, FMEA, SPC, 6-Sigma, Lean manufacturing/Value Stream Mapping, Cost reduction, 5Y, 5S and Visual management, Process improvement, Mistake proofing, Kaizen events, Pull system and Kanban, etc.

January 2017- Medtronic/Jacksonville, FL-Manufacturing Engineer/Contractor

January 2018 Responsible to evaluate existing process/equipment. Duplicate existing process/equipment at another Medtronic facility. This process includes develop supplier list for new equipment, provide technical documentation/specification to supplier, obtain quotation, evaluate quotations, select suppliers, issue PO, develop fabrication schedule, review design and complete approval process, complete Run-off at supplier floor including quality verification of equipment/process. Eliminate any problems during run-off at supplier floor and transfer equipment to new Medtronic facility. Complete Run-off at customer floor and prepare process for production cycle. Start production process. Also I was responsible for product validation including machining process validation, equipment, fixture, tooling validation, significant product characteristic validation. After completion of validation has been created validation acceptance protocol with all details of validation including set-up method, equipment, tooling, product characteristic, etc.

October 2015- Eissmann Group Automotive/Pell City, AL-Manufacturing/Development Engineer

October 2016 Responsible for implementation of new equipment/ process for car interiors including Mercedes; Jeep; Ford, Tesla, Corvette.

Developed new processes including scoring, pressing, glue spray application. Support quality department to resolve quality issues, reducing glue waste, improving part vacuum press application, developing work instruction, procedures, and visual aids. Evaluate supplier quotes and issue PO. Established quality control plan and procedures per ISO 9000, ISO 9001 Established plant floor plan. Developed plan floor for new building. Reducing cycle time and optimized current production process. Conducted tests for new development process, prepared PPAP documentation, measurement reports, and production prototypes. Meet with the customers and discuss issues, developing control plant and corrective action plan. Provided engineering changes, adjusted BOM, created technical specification for new equipment and approved new equipment design.

August 2014- Toyota/TEMA-PE/Contractor

September-2015. Responsible for implementation of GRKAI project/new V6 engine/ including machining of Crank, Block, Cylinder Head, Cam operation. Providing technical support, PML, Operation sheets, Pre-ITO; ITO, scheduling, etc. Verified cutting tools set-up and quality of the cut by measuring required dimensions on CMM.

Developed open issue deck and participate for resolving the problems. Implemented installation of conveyers, CNC machined and machining trial including production trials 1M and 2M, Production Trial. Update machining documentation, track existing documentation and provide to the plant.

Documentation includes: Control related Diagram, Instruction Manual, Spare parts drawing and list, Ass’y Drawings, CAD data, Risk Assessment etc.

Evaluated current Cycle time and assisted to calculate zone capacity.

June 2013- General Electric Company

August 2014 Advance Manufacturing Engineer/Tooling

Responsible for implementation of new trim/piercing machines and tooling for mission 1/ new refrigerators part fabrication including supplier selection, quotation, PO, design approval, run-off at supplier and plant floor, scheduling, tooling and machines try-out, production run parts verification, product design changes implementation and quality documentation, risk management.

Developed and implemented piercing process for 15/16’ FF liners, FZ liners including new piercing press, 18’ FF liners, new tooling for 30” FZ and FF liners. Developing 3D printing technology for fabrication FF and FZ liners gauging system. Controlling total tooling program cost budget - $ 4mln.

November 2012- Stenly Black and Decker

May 2013 Lean Manufacturing Engineer

Responsible for cost reduction, manufacturing improvement, lean manufacturing implementation including waist reduction, machine down time reduction, cycle time reduction, tool life improvement, quality control improvement. Implementing 5S and visual management system.

Providing presentation reports to the management to establish existing production base line and improvement recommendation. Calculating existing production yield and solutions to achieve 90%. Supporting quality department to resolve issues and improve SPC. Eliminating variables in the production process to improve SPC (Cpk > 1.33)

May 2012- Orchid Orthopedics

September 2012 Senior Engineer

Provided on-going shop floor support for all machining, metal finishing and assembly methods for medical devices. Created conceptual designs for fixtures, gages and special cutting tools. Provided technical support to purchasing and suppliers, initiating the development of manufacturing drawings and resolving technical production problems. Worked with CNC programmers, maintains manufacturing setup sheets for all machining, assembly and finishing operations. Made appropriate changes in manufacturing methods, processes through the Manufacturing Engineering change control system. Resolved technical production problems in machining, assembly, metal finishing operations working with shop operators and quality personnel. Created working instruction and procedures. Initiated and completed special projects to improve quality, productivity, reduce cycle time and scrap and increase company profitability. Maintained all manufacturing process planning documentation for assign product lines. This includes item master, item warehouse, bills of material, routings and maintenance of labor standards.

October 2005- PPG Aerospace

February 2012 Senior Engineer/Project; Tooling

Responsible for tooling design and manufacturing fixtures; molds; drill gigs, assembly fixture, gauging system to produce windows for aircraft industry around the world. Tool design and fabrication process involved composite material including epoxy and fiberglass for reinforcement.

Shape of the window created by using male or female molds fabricated as a layup of the layers with the epoxy and fiberglass, final shape was identical to the copy of 3D model of the window approved by the customer. Autoclave has been used to get final shape of the window laying on the tool. Also fiberglass solid material has been used as a tool after 5-Axis CNC machining to the final shape of the window per 3D Model. First article procedure and documentation has been created and implemented before production process started. Each shift of the production process started after first article procedures completion by the operator.

First article of the prototypes have been approved by the customer. Quality verification of the first article prototypes has been completed by using portable CMM or laser measurements technology to verify shape to the 3D model.

Final Check Fixture has been design and fabricated to verify finish product with customer and product design specification.

Tooling design and fabrication has been completed for ABS-400; EMB-21/22/23/24; Hummer; CES-067/068; GUA-033/034/035, Lear85 new programs. All programs successfully completed

` Modified several tools for existing programs for quality, productivity improvements

All programs tooling cost (average tooling cost per program-$800,000) completed within the budget and according to schedule.

Implemented tooling initiatives and saved -$260,000 every year.

Improved quality and reduced scrap

Prepared capital investment proposal and got approval from the management. ($2-3Mln. /Yr.)

July 2003 to Honda Manufacturing of Alabama /Aluminum Machining Division, Lincoln, AL

October 2005 Technical Specialist- Tooling.

Responsible for tooling support to machine AL-Casting Cylinder Head, Blocks for V-6 Engine.

Tooling inventory - $3.0 mil.; Monthly Tooling Expenses-$150,000.

Performing tooling gap analysis on the current lines situation versus the department business plan and follow PDCA process to develop and implement department’s business plan.

Provided technical leadership on machine tooling problems that cannot be satisfactorily analyzed and counter measured by team coordinators and process associates.

Investigating, propose and implement tooling activities, which is improving profitability.

Provide annual tool downtime analyses and quality improvements, reduction CPU-$1.8 /engine.

Provide accurate control of tool change points, improving tool life by redesign tool geometry, implementing diamond tool, improving cutting conditions. Documented tool tests.

Analyze and report tooling cost to Manager, Team Managers and Technical Specialists.

Support new model tooling activity, capacity up and downtime reduction projects.

Manage tool inventory, quality and drawing system.

Provide support to tool manufacturers to improve quality and cost.

Provide development of line team coordinators and production associates.

Manage tooling associates, tooling area and equipment.

Developed and implemented reduction programs for tool breakage, machining chips, cost.

Implemented new machining process for Crank and Con. Rod application using CNC, transfer line.

Developed and implemented precision shrink-fit tooling process for transfer and CNC machining process with CPU cost reduction $2.5 per engine.

June 1996 to Ford Motor Co. / Powertrain Operation; Dearborn, MI.

March 2003 Lead Manufacturing Engineer; V-Engine.

Developed tool layouts, process illustration sheets, review tool drawings, run-off equipments, order the new machining CNC and transfer lines, machining tool, developing tool management system, including tool ordering, tool regrind, production inventory, evaluate speeds and feeds, new material for Powertrain machining operations.

Developed machining process for Al casting including low and high pressure.

Proven record with specifications, purchasing, installing and maintaining aluminum machining equipment including CNC centers for drilling, milling, grinding, gun drilling, etc.

Implemented lean principles for CNC and transfer line machining process.

Multiple project ability:

Responsible for the tooling development-Duratec, Cyclone programs.

Developed machine cutting tool system for 3.0L V-6 Vulcan Cylinder Head.

Implemented 3.0L- DAMB; 3.0L; 2.0L; 2.5L-X400 Jaguar Cylinder Head machining process.

Developed Value Stream Map for machining process and tooling.

Experience leading other technical people, team leader, skills for proven problem solving.

Conducted machinability tests for valve guides, valve seats, crankshafts, connecting rods, cylinder blocks including vibration and FEA. Evaluated powder metal material specification for valve seats and valve guides to reduce forces during the cut. Optimized product design and tooling design to eliminate Bi-metal cut.

Developed APQP; FMEA, Control Plan; 8D for machining process.

Developed Lean Manufacturing process using six Sigma tool for cell CNC aluminum machining.

Using SPC implemented process control for Al-machining process with Cap more than 2.0

Green Belt certificate. /6 Sigma certificate/

Developed and conducted gun drill tests to increase the tool life for machining steel/cast iron cranks; Al heads. Investigated coolant parameters (concentration, lubricity, and hardness, GPM) to improve machinability of gun drilling operation (ratio between drill DIA and depth of cut more than 40)

Investigated new Ultra disperses Synthetic Diamond coating technology for inserts, drills, mills, etc.

Supported TMEP to increase the tool life for lock notch milling connecting rod operation and

Crankshaft milling operations.

Investigated chips formation during the drilling operation for RFF Block-CEP2.

Developed tool crib strategy including regrind process, shrink fit tooling process.

Developed ISO-9000, QS-9000 for Powertrain operation. ISO-9000 Internal Auditor.

Developed tooling home page for Internet and tooling best practice.

Developing tooling and gauging strategy for machining heads, blocks, cranks on CNC.

Developed tool life calculation system.

December Tecsyn PMP, Huntsville, AL. /Non-Union Facility

1992 to Project Development Manager.

May 1996 Developed a Cold Isostatic dry bag compaction powder metal process for application in worldwide automotive industry including Ford, GM, Chrysler, BMW, DAEWOO, Honda, and Jaguar.

Formulated a cost effective, technically advanced process for using powder metal materials for a variety of applications including cylinder liners, automatic transmission shafts,

Electromechanical motor frame, motor housing, toroid rings, valves, etc.

Devised a special secondary operation for powder metal materials applicable to green machining, honing, thermal-sizing (improvement of allowable tolerances 0.02 to 0.005 mm without machining operations), plastic impregnation, sinter bonding and Cu-infiltration.

Formulated new materials for a variety of applications including cylinder liners, compound liners

For diesel engine, Al-liners, etc.

Participated in design and development of special tools for various customer products.

Conducted complex testing of components for mechanical and tribological properties, wear and scuffing resistance, blow-by emissions, and friction-to-thermal transfer.

Fabricated a unique computerized calculation system for applications with compaction tools using Brown and Sharp CMM machine.

Education: Byelorussian Polytechnical Institute, Minsk, Byelorussia

July 1974 Masters in Mechanical Engineering/ Major-Machine building technology and machine cutting tool.

March 1991 Interactive Computer Learning System, Atlanta, and GA

Diploma of Business Programming.

September Decalb Technical Institute, Atlanta, GA

1991 Computer Assisted Design (Certificate)

1996-2003 Ford Technical Educational Certificates

1996 United States Patent.

Personal: United States citizen. Married. Fluent in English, Russian languages.

Computer literate- PC and Macintosh applications.

References: Available upon request.

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