Manufacturing/Quality/Process Engineer

GEORGE S. ZILAHI

*** ******* **., *********, ** *5905

Home: 814-***-****

Cell: 812-***-****

Email: *********@*****.***

SUMMARY

Dedicated Manufacturing and Process Engineer recognized as a valuable resource for new product

introduction, Surface Mount Technology (SMT) and Through-Hole (TH) process improvements,

production support and equipment evaluation with a high level of expertise in automated inspection

systems. Experienced in aerospace, medical, automotive, industrial and consumer electronics fields.

New Product Introduction SMT & Through-Hole processes

Process Development Automated Inspection Systems

Production Support Equipment Evaluation

Six Sigma Labor & Repair Estimates

Lean Manufacturing Customer Service

PROFESSIONAL EXPERIENCE

DRS Technologies, Johnstown, PA 2010-2013

Manufacturing Engineer

Determined and specified, revised and /or reviewed the most economic methods, operation

sequence and tooling (solder paste stencils, SMT carriers, wave and selective soldering fixtures)

for the fabrication of Circuit Card Assemblies (CCA).

Developed Manufacturing Process Instructions in CircuitCAM based on customer Assembly

Drawings and Specifications.

Generated Routers in Oracle defined by the process flow and setting lead times and resources

for each individual process step.

Managed the integration of customer Bills of Materials (BOM) and Approved Vendor List (AVL)

into the Material Requirements Planning (MRP) system and associated documentation (Product

Drawings & Specifications) required for the manufacture of customer’s product into the

documentation control system.

Reviewed and implemented all customer requested changes through Engineering Change Notice

(ECN) process to assigned products.

Supported Supply Chain responding to various component and Printed Wiring Board (PWB)

related questions from vendors to ensure appropriate material was purchased.

Completed hundreds of bid efforts (labor & tooling) for new products to determine accurate costs.

Provided Return Material Authorization (RMA) repair estimates and repair/rework instructions for

Customer Service Department.

Provided on-going engineering leadership for operations staff in the resolution of production and

process issues as required.

GHSP, Troy, MI 2009-2010

Manufacturing Engineer

Supported development of new products by providing manufacturing inputs in the design phase

using Design for Manufacturability (DFM) guidelines.

Developed and evaluated manufacturing processes by applying knowledge of product design,

fabrication, assembly, tooling and materials.

Supported builds for various prototype phases: Engineering Validation (EV), Design Validation

(DV), Production Validation (PV) and Production Release (PR).

George S. Zilahi Page 2

SPARTON ELECTRONICS, Jackson, MI 2008-2009

Senior Manufacturing Engineer / NPI coordinator

Performed as technical liaison between Customer Business Manager and project team members from

all levels of organization. Performed activities in a variety of cross-functional areas including production

planning, manufacturing, material management, and quality.

Monitored project progress/readiness and facilitated teamwork to reach project milestones/objectives

for pilot builds and Start of Production (SOP).

Generated and updated W ork Instructions.

Participated in Material Review Board (MRB), providing product manufacturing/quality expertise for

nonconforming product disposition and determined when appropriate Corrective Action (CA) was

warranted.

Ensured root cause analysis of defects and implemented process improvements to eliminate problem

recurrence.

Maintained positive relationships with customers while addressing quality concerns and requirements in

a timely and effective manner.

KIMBALL ELECTRONICS GROUP, Jasper, IN 2004-2008

Manufacturing Engineer

Supported Variable Cost Productivity (VCP) projects utilizing tools such as Six Sigma, Design of

Experiments (DOE), Lean Manufacturing and Define- Measure - Analyze - Improve - Control

(DMAIC) methodology.

Reviewed internal and external quality data for trend analysis and yield improvement using First

Pass Yield (FPY), Defects per Million Opportunities (DPMO), Statistical Process Control (SPC)

and Pareto Charts.

Assisted New Product Introduction (NPI) activities with new processes and equipment

validation/implementation using Gage R&R/MSA.

Developed W ork Instructions (WI) for manufacturing processes and Operator Control Instructions

(OCI) for various Surface Mount Technology (SMT) and Through-Hole (TH) equipment.

Initiated Engineering Changes (EC), Document Changes (DC) and Manufacturing Process

Change Requests (MPCR) ensuring they were properly addressed and implemented.

Supported Transfer of Work (TOW) activities from various sites within Kimball.

Completed budget for equipment purchase/validation/installation, negotiated global pricing to

ensure best prices for all locations.

Global process owner for Automated Inspection S ystems (solder paste and post reflow

inspection). Led cross-cultural competency team in performing research, evaluation studies and

global platform recommendations for mass production and High Mix Low Volume (HMLV)

products.

Assisted in audits & customer visits as subject matter expert in Automated Inspection Systems.

PB-TECHNIK GMBH., Hanau, Germany 2002-2003

Applications Engineer

Participated at international electronics trade shows (APEX - USA, Productronica - Germany;

SMT Nurnberg - Germany) exhibiting various equipment.

Installed, programmed and maintained:

Automated Optical Inspection (AOI) systems: Hypervision, Agilent SJ-10, SJ-50

Hover Davis Direct Die Feeder (DDF)

Conducted equipment demos and trained customers.

Maintained regular contact with customers and provided technical support as needed to maintain

customer satisfaction.

George S. Zilahi Page 3

FLEXTRONICS INT. LTD., Zalaegerszeg, Hungary 1999-2002

Senior AOI Test Engineer / SMT Process Engineer

Developed test processes and conducted benchmarks on Automated Optical Inspection (AOI)

systems (Hypervision, Orbotech Trion 2340 and ViTechnology VI3000) and X-ray (Agilent

HP5DX).

Generated programs for new products and sustained ongoing optimization of programs in

production.

W orked closely with Quality Engineering in gathering/managing Statistical Process Control (SPC)

data, and analyzing the root cause of manufacturing defects improving the through-put yield and

overall quality of products.

Held AOI & X-ray Operator/Maintenance/Programmer training for Engineering and Operations

staff for accurate operation of equipment.

Provided troubleshooting and increased through-put on Pick & Place machines by optimizing

machine performance.

EDUCATION

BS Degree in Electrical Engineering

Technical University, Electrical Engineering Faculty, Cluj-Napoca, Romania

COMPUTER SKILLS

CircuitCAM Oracle Omnify

SAP GerbTool MiniTab Statistical Analysis

Quality Companion Valor Cimbridge

Visio Easy Label BAAN

W indows W ord Excel

Project Outlook PowerPoint

OS/2

TRAINING

IPC-A-610 Certification – Johnstown, PA

2012

CircuitCAM Training – Philadelphia, PA

2010

Valor Training – Largo, FL

2008

2007 Kelley Business School - Project Management Training - Jasper, IN

2007 Lean Manufacturing Training - Jasper, IN

2005 Corrective Action and Problem Solving - Jasper, IN

2005 Six Sigma Green Belt Training - Jasper, IN

2004 Orbotech Automated Optical Inspection (AOI) - Programmer Training - Irvine, CA

Hover Davis Direct Die Feeder (DDF) – Programmer & Service Training - Rochester, NY

2002

HP5DX (Agilent X-ray) – Programmer Training - W inersh, United Kingdom

2000

1999 Philips Automated Pick & Place (ACM, FCM) - User & Maintenance Training -Eindhoven, Holland

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