IGOR MACHULA

**** ******** ****, *******, *** *Z*

416-***-****; ac7ri5@r.postjobfree.com

OBJECTIVE:

To obtain a challenging career utilizing and expanding my

Process engineering /Metallurgical / Material Science within a progressive company

AREAS OF EXPERTISE

20 years of international management experience in design, development and implementation of processes in Aerospace, Energy and Automotive Industries.

Developed expertise in techniques and processes in Aerospace Design, Development and Manufacturing such as, Material Science/Metallurgy, Materials selection, Heat Treatment, Corrosion, Welding, Bonding, Brazing, PVD coating, Hot Isostatic Pressing (HIP), 3-D Printing, Powder metallurgy, Sputtering process, Vacuum technique, Cryogenic systems; Die & Lost-wax Casting

Extensive experience in methods of Failure analyses through Mechanical Testing Experienced with specialized knowledge of various Non-Destructive Testing methodologies including Ultrasonic Testing (UT), X-ray and Gamma Radiography (RT), Liquid Penetration (PT), Acoustic Emission Testing (AE), Eddy Current methods

Experienced with technique from GE, Siemens, Rolls-Royce, Pratt & Whitney, Elliot, Andreas Hoffer, ABB, LEYBOLD HERAUSs (Oerlikon), AVURE Technologies (ASEA), Phillips, Bodycote, DAY VAC, Honeywell; Vacuum technique and Cryogenic systems

ISO 9000/1/2, TS 16949, ASME, ASTM, AWS, CWB, GE Standards and Quality Planning tools (APQP, PPAP, CP, FMEA); Execute Root Cause Analysis (RCA), making Corrective Actions (CA) and Preventive Correct Actions (PCA), MRB activity

Expert in quality improvement methodologies such as 8D, TQM, Lean Manufacturing, 6Sigma, APQP, Toyota System

Managed Technical /Quality aspects related to Installation, Maintenance and Industrial Testing of equipment, SQE Managed Projects from Start-up, Supply chain, Identification priorities, Special Process, Equipment & Tooling needs, Calibration, Qualification Package, Standard Plans Assessment; Consumables, Fixtures, Cages, Vendor Qualification, making manufacturing optimize time- till critical related Expenses, Expenses forecasting and Variance analysis

PROFESSIONAL EXPERIENCE

Materials Specialist/Project Engineer

Husky Injection Molding Systems, Ltd. 2015 Aug.-present

Technical Lead of the process implementation new technologies in manufacturing

Quality Leader /Quality Department

Commercial Spring and Tool Co. Ltd., automotive 2013 – 2015

Lead implementation of Quality Assurance and Management processes and systems for spring Heat Treatment and Coating for automotive industry (GM, Chrysler, Ford, Honda, and Toyota).

Manage implementation of new methods and Quality tools for improving Quality responsibility level, i.e. ISO 9000/1/2, TS 16949, ASME, ASTM, AWS, CWB, Quality Planning tools (APQP, PPAP, CP, FMEA); Execute Root Cause Analysis (RCA), making Corrective Actions (CA) and Preventive Correct Action (PCA), MRB, SMA for DT and NDT.

Develop and put in place an in-house quality assurance training for personnel; coach and supervise the trainers among the staff

Develop and place in operation Quality planning tools.

Develop and implement Quality Complaint Data.

Quality Management & Engineering 2011 – 2013

Contract-based projects leader

Organized and led the teams for particular Quality Improvement Projects as Project Leader

Optimizing Turbine & Generator Overhauls in Bearing 2013

Led the Quality team to establish, implement and put in place maintenance of the quality management system (ISO 9001:2008, API Q1);

Guided the team in modified training content to improve quality, productivity and reduce cost; team implemented continuous improvement projects.

Oversaw QA reports; Testing and Inspections; Balance and Alignment; Failure Analysis; Diagnostics and Troubleshooting; Performance Testing; minimizing risk impact to business and customers.

Handled failure analysis; supervised corrective and preventive actions in response to customer complaints.

Managed development and putting in place company quality documentation procedures, supervised creation of quality manuals.

Aircraft manufacturing 2012

Improving Quality System by 6Sigma Lean quality Methodology

Led the team of to successfully implement and maintain Quality management system (ISO9001:2009, API Q1).

Oversaw development of personnel training to build quality awareness, manage suppliers’ performance and conduct audits.

Coordinated RCA and implementation of CA for process related concerns.

Prepared recommendations for changes to systems, procedures, work instructions

Supervised preparation of QA statistical analysis reports.

Oil & Gas industry 2012 Improving QM system Metallurgical products manufacturing

Set inspection strategies based on RBI studies and occasionally initiated and led RBI studies; performed static equipment inspection. Approved modifications and repairs of static equipment; Supervised NDT contract services, inspection of received materials, manufacture and repair to ensure compliance with specified requirements; Contributed to RCM studies and RCA studies.

Ensured that advice given on inspection, maintenance, application, procurement, modification, design, construction and contract of static equipment was fit for purpose and customer focused.

Conducted technical negotiations with the S-RBI process, was responsible for RBI implementation and dissemination of RBI philosophy in Operations and Maintenance.

Prepared and contributed to internal and external technical audits and studies: FAIR, HSE, RRM, HAZOP, and RCA.

Lead Quality and Methods Engineer

GE Energy, new Power Technology Center, Kaluga June 2010 – June 2011

Established and led Design, Develop and Implement Management, Quality Assurance Processes and systems for a newly established gas turbine repair plant

As a result, the plant was successfully certified with ISO 9001/2, AWS, ASME, ASTM, and Quality planning tools and was placed in operation on schedule.

Planned and implemented repair procedures for gas turbine parts: Fuel Nozzle and Combustion, Turbine and Compressor hardware including rotating and stationary components based on GE and non GE documentation.

Lead GE Service Qualification Process Procedure: special process, equipment & tooling needs, calibration, special processing needs; HVOF Coating; Welding TIG/RE- WPS (Welding Procedure Specification)- SP-41-1001 ASTM-1742, ASME Section IX, ISO EN287, AWS D17, ASTM E1417, ASTM E1742: NDT control -ASTM E165, ASTM E1220, ASTM E1316, ASTM E1417.

Standard, qualification package supporting documents, standard plans assessment; consumables, tooling, fixtures, cages and vendor qualification and customer needs of high reliability parts, materials and processes ISO 9000,9100,9120, NADCAP, ASME, ASTM, AWS, CWB, GE standards and quality planning tools (APQP, PPAP, CP, FMEA); PED; TUV;OEM; execute root cause analysis (RCA), corrective actions (CA) and (PCA)

Contacted customers and suppliers, discuss specific quality issues; led and implemented reliability programs & plans, conducted Internal Quality Audit based on Lean & 6Sigma methodology; managing quality responsibilities as assigned including: Complaint Data, Compliant CA/PA Planning, Execution, and Effectiveness Checks, Complaint file Closure and Trending

Conducted training to personnel, responsible for the Quality of all in-house manufactured products

Product Assurance Engineer, Materials

MacDonald Dettwiler Space and Advanced Robotics Ltd.

(Formerly MDA Corporation) Aerospace, Brampton, Ontario, Contract 2009

Led activity of developing and controlling parts reliability requirements, including parts for space and high reliability programs /Space Station Remote Manipulator System (SSRMS) – CANADARM-2/

Selected and controlled all materials and processes to ensure that functional, environmental and contamination control requirements are met.

Generated part program plans, procurement and test specifications and part application analyses.

Documented and presented results of QE/QA, NDT and control test at milestone reviews.

Developed and maintained relationships (telecoms, meetings, briefings) with the customers, subcontractors and vendors (NASA, Canadian Space Agency (CSA)).

Participated and supervised manufacturing process of systems with respect to materials design features

Selected and controlled all materials and processes to ensure that functional, environmental and contamination control requirements are met.

Quality Engineer

ARMOTOOL, Toronto, Sputtering of High Precision parts, Toronto 2007 – 2009

Led Quality Department

Provided complex PVD /plasma/ sputtering, TiN, TiCN, AlTiN, AlCrN, VC, ZrN, DLC Sputter Deposition, Sputter Mirrors, Physical Vapor Deposition, PVD, Thin Film Deposition, Plasma Processing, Substrate. Provided complex coatings for Cutting, Punching and Forming, Moulding, Die Casting and Precision Components

Monitored quality standards in manufacturing and finishing for sputtering.

Evaluated the activities of Quality Control Department.

Developed Inspection System Selected effectively combining materials for specific purposes.

Assisted in the design of custom-made products /PVD coating tools.

Process Engineer

TURBO Inc., Pumps equipment productivity, Russia 1996 – 2006

Hydraulic, steam and gas turbines, TPU units on their basis for various working mediums

Conduct the Technical Development Department and Quality Control Department to start-up productivity turbo and reached ISO 9000 level in processing Developed QA/QC system Started-up productivity turbo as a leader of the Technical Development Department, and reached ISO 9000 level in processing

Monitored and improved the efficiency, output and safety of the plant.

Executed quality control & elimination of in galvanic, heat-treatment, and casting.

Designed technologies for equipment, installed control systems, initiated and upgraded processes

Controlled and specified the technological process.

Performed failure analyses & correction actions for defects in processes.

Process Engineer

CDBA, Design Bureau, Russia, Aerospace 1985 – 1996

Aerospace/ Propulsion Systems, Liquid Rocket Engines/LRE, Space flight programs/Space missions

Led and managed the projects, supervised a team of engineers, technicians and technologists during that task Promoted from manufacturing engineer to Process engineer/Project Manager

Initially gained experience of range of projects within the Space mission activity

Continued working on projects, eventually moving into a project manager role

Successfully created & implemented improved technologies for stressed details /parts of the propulsion systems/jets/turbines as are:

Cladding; Brazing; Welding; Heat treatment; Casting; Cryogenic Methods; Vacuum pumps; Metallurgy; Blade Steel; Steel Stabilization; Blades; Carbide Density; Secondary Carbide Density; Pressure Vessels; Ti-8Al-Mo, Ti-6Al-4V, Rene85, Rene 142, Hastelloy G30X; Incoloy 690,792

Devised methodology and techniques for the production of superalloys and improvement of existing methodology and technique by decreasing errors; oversaw production of near net shape (NNS) components by HIP (HOT ISOSTATIC PRESSING) process / HIP for high performance parts.

EDUCATION

B.Sc. Physics of Metal/ Metallurgy Engineering, Technical University, Russia

Green Belt 6 Sigma / GE Energy

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