JOHN EDWARDS

**** **** ***** • Nashville, TN ****1

Cell: 843-***-**** • acca0d@r.postjobfree.com

SENIOR MANUFACTURING ENGINEER

Versatile, resourceful, and goal-oriented Manufacturing Engineer with extensive hands-on experience developing,

implementing, and evaluating production processes and process controls from initial conceptualization through

launch and ongoing operation. Proven results in upgrading and creating reliable, repeatable, capable, and cost

effective processes by exploring facts and data, parameter optimization, tool design and selection, fixture design

and development, gauging and equipment selection. Self-directed team leader capable to build strong working

relationships with all stakeholders. Able to see the big picture, focus on the critical details, and prioritize multiple

projects in high-pressure and deadline driven environments. Committed to exceeding expectations through

creative idea generation, collaborative problem solving, and disciplined decision making.

AREAS OF EXPERTISE

• CNC Machining & • Lean Manufacturing • Project Management

Programming

• Metal Stamping & Tooling • Identify & Eliminate Waste • AIAG APQP

• Data Driven Problem • Process Development • Facility/ Cellular Layout

Solving

• Process Capability Analysis • Capital / Tooling • Process Capacity

Justification Planning

PROFESSIONAL EXPERIENCE

CONTRACT MANUFACTURING ENGINEERING CONSULTANT, Electrolux, Springfield, TN, May

2013-November 2013 (All Contract Obligations Satisfied)

Responsible for coordinating, planning, evaluating, and implementing corrective actions for productivity issues in

the primary stamping and automated fabrication equipment.

• Established systems for data collection and analysis. Compiled the collected data to focus and

drive continuous improvement activities and waste reduction within the stamping and tooling

departments.

• Coordinated SMED events; defining internal and external work elements and dividing changeover

activities between employees to reduce changeover times from 35 minutes to an average of 15 minutes.

• Developed repeatable tool location systems between presses allowing dies to be setup efficiently

between each press.

• Managed tooling repair schedules with outside tooling suppliers eliminating expediting and

shortages of stampings.

• Developed a capacity strategy for the stamping department based on product volume in order to

plan overtime or out-sourcing of tooling; eliminating part shortages in the assembly departments.

CONTRACT MANUFACTURING CONSULTANT, Martinrea, Hopkinsville, KY Jan 2013-May 2013

Responsible for coordinating, planning, evaluating, and implementing corrective actions for quality issues on four

product lines.

• Utilizing basic tools of Quality including: Flow charts, Ishikawa diagrams, check sheets, histogram,

control charts, and Pareto charts to implement permanent corrective actions for customer, supplier, and

internal quality concerns.

• Developed and revised quality documentation and provided personnel training per TS requirements.

• Reduced customer quality concerns by 70% for product lines under my responsibility.

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CONTRACT MANUFACTURING ENGINEERING CONSULTANT, VAN- ROB, Manchester, TN, 2012-

2013 (All Obligations Satisfied)

Instrumental team leader for launching 26 new aluminum MIG Welded assemblies for the GM Y1XX (2014

Corvette) program. Responsible for the coordination, planning, evaluating, and acceptance of welding and

fastener assembly equipment.

• Created facility layout for product assembly utilizing part volume requirements, process mapping,

equipment design, ergonomics, and floor space utilization.

• Evaluated and resolved design issues for equipment, tools, and fixtures for welded assemblies

including safety, error proofing (Poka-Yokes), operator interface, and floor space minimization.

• Resolved tooling, fixture, and process quality capability issues.

• Implemented the new products and processes utilizing AIAG APQP procedures creating Process

Flow Charts,and PFMEA's.

• Defined Aluminum MIG welding parameters including torch angle, Argon Flow Rate, push

welding, part cleaning requirements, feed rates, and weld parameter settings from prior experience and

DOE testing.

CONTRACT MANUFACTURING ENGINEER CONSULTANT, PARKER-RACOR, Beaufort, SC • 2010 –

2012 (All obligations satisfied)

Manufacturing and Quality Engineer responsible for braided and formed tube assembly processes and machining

processes in the manufacture of diesel filtration systems for Diamler, Navistar, and Detroit Diesel.

• Permanently resolved tooling, gauge, fixture, and process quality issues utilizing facts and data,

quality tools, statistical analysis, and root cause analysis.

• Implemented new products and processes utilizing APQP procedures utilizing proven

manufacturing and quality tools.

• Planned and developed tools, fixtures, and equipment for machining, assembly, and testing.

• Initiated and lead teams to resolved safety, quality, and productivity issues through proven

engineering and root cause analysis.

• Engineered improved process flow and processing resulting in defects detected at testing from 5%

to 1.5%.

• Launched 15 new products; meeting planned PPAP dates with all documentation and customer

approval.

• Performed machining process improvements, implemented new tooling and fixtures; reducing

PPM defects by 80%.

EXACTECH INC., Gainesville, FL • 2008 – 2009 (Reduction in Force)

Senior Manufacturing Engineer

Built tools and fixtures, implemented processes, and authored quality documentation for new product launches

including Standard Operating Procedures, Engineering Standards, Process Work Instructions, lot control, record

maintenance, and preparation of FDA submissions.

Championed process capability and quality improvements for current and new products. Wrote operator work

instructions including record maintenance, product inspection, and process control documentation.

Developed, wrote, and performed Process Validation and Verification including Installation Qualification (IQ),

Operational Qualification (OQ), and Process Qualification (PQ). Conducted on-site visits to domestic suppliers to

implement tooling, quality, cost, and process improvements.

• Reduced PPM defects resulting in $100K savings.

• Served as Team Leader (Quality, Manufacturing, Manufacturing Engineering, and Product Engineering)

for set-up reduction program for knee implants reducing time from 45 to 15 minutes.

• Led the design and build of automated Fluorescent Penetrant processing equipment and an inspection

station that generated a $4.00/part cost savings and drove further in-sourcing of product.

JOHN EDWARDS: 5009 Meta Drive • Nashville, TN 37211

AEROTEK CONTRACT ENGINEERING, VOLUNTEER ENGINEERING, JOHNSON CONTROLS

Knoxville, TN (2007-2008), Nashville, TN (2003-2005) (All obligations satisfied)

Senior Advanced Manufacturing Engineer

Resolved tooling, gauge, fixture, and process quality capabilities using Six Sigma, 8D’s, and SPC. Implemented

new products and processes utilizing APQP procedures with Process Flow Charts, PFMEA, Control Plans, Gant

Charts, MSA, and all other APQP tools. Planned and developed protocols, documents, tools, fixtures, and

equipment for high volume machining, stamping, assembly, and welding. Initiated and lead teams to resolved

safety, quality, and productivity issues through proven engineering and root cause analysis.

• Engineered improved flow, error-proofing, and defects reduction from 500 PPM to 20 PPM in 12

months.

• Launched 15 new products; meeting initial PPAP date with document, gage, capability, and

product approval by the customer.

• Performed Gap Analysis, identifying and eliminating seven kinds of manufacturing wastes.

• Performed process improvements; reducing PPM defects from 10000 to 500 in 18 months.

CVG – NATIONAL SEATING, Vonore, TN • 2006 – 2007 (Reduction in force)

Division of Commercial Vehicle Group producing showcase air ride suspension seats for commercial truck

OEMs.

Senior Process Engineer

Designed tooling, equipment, and managed budgets for the successful launches of many new products. Developed

TS and QS documentation including lot traceability, programs, PFMEAs, Control Plans, and work instructions.

Traveled to domestic and international customer and supplier facilities implemented new tooling, improved

supplier quality, reduced cost and lead-time of outsourced product.

• Initiated, lead teams, and resolved 8-D quality issues providing customers with containment and

permanent corrective actions.

• Dramatically improved defect rates from 500 PPM to less than 50 PPM in eight months.

• Developed and managed new tooling and products for CVG’s China Operations.

NORTEK INDUSTRIES, Maryville, TN • 2005 – 2006 (Company sold. New owner brought own management

staff)

Automotive Tier II safety restraint stamping supplier.

Engineering Manager

Supervised a staff of 11 including Tool & Die Journeymen, Maintenance Technicians, and Engineers. Developed

ISO 9001 procedures for Tooling, Maintenance, and Engineering Departments. Managed all facility maintenance,

tool design, and manufacturing engineering.

• Reduced set-up times two hours from last-off to first-off through lean principles and automation.

• Refurbished 35 dilapidated progressive stamping dies to customer quality specifications and

completed project under budget and within planned lead-time.

• Investigated and resolved quality issues utilizing facts and data, statistical analysis, and other

quality tools.

• Utilized AIAG APQP process for customer PPAP's with full documentation and approval parts.

SIEMENS DIESEL SYSTEM TECHNOLOGY, Blythewood, SC • 2000 – 2003 (New programs cancelled)

Tier I manufacturer of diesel fuel injectors for International Harvester and Ford Motor Company.

Senior Advanced Manufacturing Engineer

Managed a staff of 15 including Manufacturing Technicians and Team Leaders in the Machining Department.

Project manager for the selection and installation of six high precision ten station rotary CNC machining

equipment worth $20 million, including process development, tool design, fixtures, programming, and APQP.

Developed and implemented six automatic hard turning with post process gaging replacing a plan for

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conventional grinding that yielded $16 million in capital equipment savings and $300K in annual operating cost

savings. Improved major processes resulting in $15 million in capital savings and $400K in annual cost savings

through tooling, fixture, and process modifications.

• Developed processes, fixtures, and tooling for all in plant machining process for two new diesel

fuel injectors.

• Initiated, lead teams, and resolved 8-D quality issues. Initiated and lead root cause analysis teams.

• Provided reports of short term and permanent corrective actions to OEM customers.

• Key Six Sigma team leader on machining improvement project resulting in $5 million annual

savings.

YALE SECURITY, Lenoir City, TN • 1993 – 1999 (Recruited by Major Tool for better incentives and

advancement).

Manufacturer of commercial and residential lock hardware.

Senior Manufacturing Engineer

Project leader for conceptualizing, specifying, and managing a $12 million capital investment in high-precision

CNC machining and turning. Directed all aspects of machining process development, tooling, fixtures, programs,

and quality documents. Wrote the TS/ISO documents for project management, equipment specifications, and

work instructions.

• Negotiated $800K in capital savings and $75K in annual tooling savings.

• Developed and implemented 10 axis CNC Swiss turning processes over conventional turning,

followed by manual milling, drilling, and broaching lock cylinder plugs, yielding a $5 million capital

equipment savings over 10 station rotary equipment.

• Developed a demand pull process inventory system resulting in a $2 million one-time inventory

savings, and $400K in annual labor and overhead savings.

• Team leader in final assembly on continuous improvement projects yielding $250K in annual

savings.

• Produced $200K in annual savings through tooling and process improvements on conventional

single and multi-spindle machining equipment.

EAGLE BEND MANUFACTURING/MAGNA INTERNATIONAL, Clinton, TN • 1990 – 1993 (Recruited by

Yale)

Manufacturer of automotive tier I structural metal stampings and welded assemblies.

Manufacturing Engineer / Program Manager

Orchestrated major model year changes for an $18 million annual CT-120 Ford Motor Company program

including product and tooling quotations, writing tooling and equipment specifications, managing equipment and

tooling builds, equipment and tooling acceptance. Spearheaded a $12 million annual sales program for SN-95

Mustang launch with 56 stampings and 10 welding assemblies for Ford Motor Company. Organized and led the

implementation team which included Tooling Engineers, Quality Engineers, Tool and Die makers, Assembly

Engineers, and Manufacturing Technicians. Collaborated with vendors, peers, management, customer

engineering, and purchasing on all aspects of the Ford business, including product, gage, and tooling

specifications, and quotations. Developed work instructions, gage instructions, and all APQP documentation.

Reported weekly status to management and Ford on program launch. Maintained process documentation,

engineering changes, purchase orders, incurred costs, and communications.

• Domestically sourced components made from special material for a safety critical product

utilizing statistical strength comparisons and vehicle crash test validation generating $2 million in shared

annual savings.

• Initiated, lead teams, and resolved 8-D quality issues. Initiated and lead root cause analysis teams

for problem solving. Provided reports of short term and permanent corrective actions to OEM customers.

JOHN EDWARDS: 5009 Meta Drive • Nashville, TN 37211

CARRIER CORPORATION - ALLIED PRODUCTS DIVISION, Knoxville, TN • 1988 – 1990 (Recruited by

EBM)

Manufacturer of commercial and residential heating and cooling equipment.

Manufacturing Engineer / Production Supervisor

Led 50 production, quality, and engineering technicians on four assembly lines. Maintained employee records,

handled performance evaluations, disciplinary actions, and employee recognition. Ensured a safe work

environment through ongoing maintenance and use of best ergonomic practices. Reported daily productivity to

management. Created work instruction visual aids for each operation on various products. Utilized pre-determined

time standards and time studies for optimal line balancing.

• Reprocessed and revised documentation of current products increasing productivity by 10%.

• Launched a new electric heat program with an overall reduction of 25% in costs versus plan.

VOLUNTEER TOOL & DIE, Cookeville, TN • 1986 – 1988 (Recruited by Carrier Corporation)

Manufacturer of metal stampings and machining for Water Heating Industry.

Engineering Manager

Directed two Tooling Engineers, four quality technicians, and three maintenance technicians with responsibility

for implementing engineering changes, safety training, quality, and process improvements. Responded to

customer quality concerns. Conducted quality training for machine operators. Developed written protocols and

quality plans for all products. Documented product validation, verification, procedures, and work instructions.

• Established predictive tooling maintenance based on trend analysis of recorded dimensional data.

• Implemented QDC training for setup technicians that reduced press changeover times from 2

hours to 30 minutes with zero capital investment.

• Developed demand pull KANBAN system for replenishment of manufactured and purchased

components reducing overtime and expediting costs by 75%.

EDUCATION

Bachelor of Science in Industrial Engineering - Tennessee Technological University, Cookeville, TN

SPECIALIZED TRAINING

• Six Sigma Green and Black Belt Team Training

• EIA/ISO (G-code) and Conversational Programming for Turning and Milling

• Toyota Just-in-Time Manufacturing, Lean Manufacturing & QS 9001

• APQP, TS16949 Quality Operating System, ISO 14001 Environmental

• ASME Y14.5-2009 Geometric Dimensioning and Tolerancing Certification

COMPUTER SKILLS

• CAD: AutoCAD, Mechanical Desktop, Inventor, and Solidworks

• Microsoft Office: Word, Excel, Powerpoint, Access, and Project

• Statistical: MiniTab Statistical Software

• APQP: MPACT and AquaPro APQP Software

• CNC: EIA/ISO (G-code), Mazatrol, FANUC and Siemens CNC Programming

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