Engineer Manufacturing

MARK AYERS

**** ****** ** ***** ******, MS ***** 901-***-**** **********@*******.***

SKILLS SUMMARY

Automation Lean Manufacturing Process Enhancement 5 S

Machine Design Product Design Schematic Generation ME10 (CAD)

Inventor 13 Sheet Metal Fabrication Allen Bradley PLC Cadkey 5.0

AutoCAD Project Management MOST Time Study Solidworks TRAINING

Inventor Kaizen PFMEA MiniTab

TPM SPC Positive Power Influence Finance

Lean Manufacturing SLC 500 Programming Leadership Challenge DFMEA EDUCATION, DEGREES AND CERTIFICATION

Master of Business Administration / 2000 / Indiana Wesleyan University / 3.97/4.0 GPA

Bachelor of Science, Mechanical Engineering Technology / 1995 / Purdue University / 3.13/4.0 GPA

Associate of Applied Science, Supervision / 1993 / Purdue University / 3.23/4.0 GPA

Lean Manufacturing Certification / February 2004 / Black River Technical College / Paragould, AR PROFESSIONAL EXPERIENCE

Regional Automation Engineer / Orchid Orthopedics / Memphis, TN / September 2017 – Current Surgical Implant Manufacturer, manufacturer innovative surgical implants and instruments

Responsible for the implementation of automated manufacturing systems for labor reduction and efficiency among (2) manufacturing plants located in Arab, AL and Memphis TN;

Justify capital investments with labor reduction, quality improvement and labor efficiency;

Solicit vendors for said investments for competitive quotes;

Serve as the Project Manager for capital equipment development and installation to set schedule; Sr. Upstream Manufacturing Engineer / Smith & Nephew / Memphis, TN / September 2015 – September 2017 Advanced Surgical Device Division, manufacturer innovative surgical implants and instruments

Ensure new product launch schedules by resolving delays in process characterizations governed by PFMEAs;

Drive design changes for manufacturability and to resolve issues associated with design transfer tasks;

Collaborate with Quality Engineers for Measurement System Analysis issues;

Develop BOM and Matrix structure for new product launch;

Create routings in SAP for new product launch;

Support Quality Engineers for Process Characterizations; Lean Manufacturing Engineer / Parker Hannifin / Olive Branch, MS / November 2010 – September 2015 Chelsea Division, manufacturer of power take-offs for the working vehicle indusrty

Updated existing equipment with A-B SLC 504 for test accuracy and user-friendly spreadsheet application for ease of new product introduction and release of vendor dependency;

Redefined existing test equipment for a 14% increase in FPY equivalent to $23,000 annual savings;

Designed and built an automated assembly table for a $48,000 annual savings with a $25,000 investment;

Designed and built a gated automated shim machine that measured a bearing assembly and housing to specify the required shim thickness for specified gear end play for 23% reduction in warranty claims;

Designed and built a gated automated machine that tested finished product for test conformity to ensure quality products for a 12% reduction in warranty claims;

Hands-on support of said equipment for operator training and continuous improvement;

Complied with safety standards to design press fixtures for hands-free operation;

Established control plans, work instructions, PFMEA, and tooling for new product launches. Partnership / Wiley Imports / Memphis, TN / July 2008 – November 2009 Mercedes Benz complete service and salvage center

Product Engineer / Allen Engineering / Paragould, AR / August 2006 – February 2008 OEM manufacturer of commercial and residential concrete finishing equipment

Responsibility for redesigning $13M product line using Inventor together with Lean consideration for robust products and a yearly projected increase of 18% through design for manufacturability and assembly;

Standardized products and fixtures for automated welding and to ensure proceeding models consisted of common components for rapid market introduction with 25% labor reduction and 10% weight reduction;

Evaluated and determined manufacturing requirements for part production including material, configuration, volume, quality and costs;

Established mechanical and electrical engineering drawings via appropriate BOMs, routings and instructions;

Implementation of product revisions with testing and assessment for validation;

Prepared quote summaries for test equipment, machinery, and tooling;

Investigated, tested, evaluated and reported on competitor products;

Secured quotes, created prototypes and coordinated new products with production;

Performed revisions to equipment as necessary to achieve production objectives;

Hands-on fabrication of components for equipment/products being built or manufactured. Sr. Manufacturing Engineer / L.A. Darling / Paragould, AR / December 2003 – October 2005

$150M manufacturer of retail display shelving for consumer products

Implemented product and labor modifications through capital justification of equipment and saved $148,600 over 15 months through installation of 5 exclusive projects involving progressive stamp/form dies;

Led installation of $1.1M monorail powder coat line at 28fpm for manufacturing expansion;

Generated schematics for AB 1336 conveyor drives with AutoCAD 2000 for powder coat line;

Purchased roll formers and tooling to create rib-style shelving for labor and material reduction;

Managed/coordinated installation of new department (mills, presses, power distribution, etc.) with contractors and union employees, successfully establishing the department on schedule and 26% under budget;

Responsible for on-schedule installation of ITW Gema powder guns and equipment for coating of cold-rolled steel products; hands-on management with wiring and utilization of Maintenance personnel;

Using Lean manufacturing techniques with 5S, organized floor personnel improving efficiency, accuracy, ergonomics and safety utilizing MOST and AutoCAD 2000 for time studies, labor combinations, and tooling fixtures - increasing productivity 320 to 400 units per shift. Manufacturing Engineer / Carrier Corp. / Collierville, TN / June 2002 – August 2003 Subsidiary of United Technologies, leading manufacturer of residential air conditioners

Supervised contractors in relocation of coil-manufacturing department ($4M book value) to complete project and initiate new department on schedule and within budget;

Maintained and improved 60-ton Burr Oak fin presses at 180 spm, Phinney progressive fin dies, Burr Oak copper tubing benders, and Tridan coil expanders - minimizing downtime and improving efficiency;

Composed operating instruction guides, safety instructions, and TPM checklists for hydraulic presses and coil-manufacturing equipment;

Managed and supervised multiple hands-on projects for maintenance technicians and contractors, including equipment rebuild and replacement;

Troubleshot equipment failure using RSLogix 500 to identify faults in PLC programs, quickly bringing equipment on-line and minimized downtime;

Achieved ACE (Achieving Competitive Excellence) Silver Status documenting procedures and practices. Project Manager / Facilities Engineer / Howmet Corp. / LaPorte, IN / May 1998 – April 2001 Subsidiary of Alcoa, investment-casting company of turbine components for the aerospace industry

Operated with the techniques of Total Preventative Maintenance (TPM), ACE, 5S Principles and Kaizen achieving positive business results and defect reduction;

Designed and supervised installation of automated mold transfer for a 30% production increase;

Directed feedback to management for subordinate and contractor performance reviews;

Designed under-hearth-fired refractory furnaces with AutoCAD for rebuild improvements establishing uniformity and efficiency for temperature ranges;

Corresponded to demanding manufacturing procedures for vacuum casting and heat-treating processes below 1/2 micron;

Capital equipment justification, fabrication oversight, installation, and runoff;

Designed 30 to 300lb induction coils for Equiax casting units. Machine Designer / Weldun International / Bridgman, MI / October 1996 – May 1998 Subsidiary of Robert Bosch Corporation, manufacturing automation assembly system

Automated equipment design utilizing Allen Bradley PLC with servo & stepper motors, pneumatics, and hydraulics with accurate and precise positioning for manufacturing efficiency;

Completed exclusive pick and place assembly system designs for Chrysler, Ford, GM, Solar Turbines, and Ciba Optical using AutoCAD 14, Cadkey 5.0, and ME10;

Managed machining and assembly of my designs and collaborated with tooling personnel for line construction and failure evaluation using FMEA;

Established accurate positioning of substations with close GD&T of detailed parts, tooling and fixtures, sustaining a customer manufacturing capability of 1.67 CpK (6 Sigma). Mechanical Engineer / Quality Industrial Service / LaPorte, IN / Nov. 1993 – October 1996 An OEM of robotics and automation equipment

Quoted projects according to PLC requirements, estimated labor, materials and design time;

Designed equipment modifications with AutoCAD and Cadkey enhancing quality and reliability;

Prepared Gantt chart for project communications and milestones ensuring project completion dates;

Prominent customer relations throughout all stages of equipment design, assembly and follow-up on completed projects, guaranteed satisfaction and maintained business distinction;

Created schematic prints and layouts with VIA Schematic, EEPD+, and Protel;

Hardwired equipment, PLCs, motors, relays, sensors, limit switches, etc. for OEM machinery;

Trained manufacturing personnel on new equipment and process enhancements.

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