Engineer Manufacturing

CHARLES A. BOYER

Home: ***/***-**** *** *

Cell: 815/289-5217 Shirland, Illinois 61079

E-mail: ********@*******.***

SUMMARY OF QUALIFICATIONS

Manufacturing Engineer with thirty plus years experience in the design and manufacturing of precision mechanical and electro-mechanical components for industrial, automotive and aerospace products. Skills include reviewing designs for manufacturability, tool design, capitol equipment justification, routing, processing, cost estimation, cost reduction and plant layout.

PROFESSIONAL EXPERIENCE

BAKER MFG 2010-2014

Manufacturer of pumps and municipal water products.

Senior Manufacturing Engineer responsible for capitol equipment appropriations, cost estimation, cost reduction, tool/gage design, routings, process development and problem solving at all Baker facilities in Wisconsin, Pennsylvania and Florida.

WARNER ELECTRIC BRAKE, South Beloit, Illinois 2005-2010

Senior Manufacturing Engineer assigned to component part insourcing, routing, CAD drawing, CNC lathe and machining center programming, cost estimation and fixture design. Appropriated and implemented a $600K machining cell with 45% ROI that included a twin 16” chuck Okuma lathe, Bridgeport high speed machining center, 200KVA resistance welder, and 75 ton press.

AEROTEK/AMEROCK, Rockford, Illinois 2004-2005

Manufacturing Engineer contracted to document operations and processes to coincide with Amerock’s move to Monterrey Mexico.

WARNER ELECTRIC BRAKE, Roscoe, Illinois 1989-2004

Manufacturer of electric clutches and brakes

Manufacturing Engineer Vehicular Group (1998-2004) responsible for the entire product line of after-market vehicular clutches. Assigned to do cost reductions, cost estimating, design reviews, equipment justification and plant layouts.

Awarded two patents for resolving design issues on an OEM compressor armature, resulting in approximately $1 million in profit.

Organized Kaizen events to implement part flow improvements and cost reductions in a lean manufacturing environment.

Replaced welded assemblies with one-piece forged blanks, reducing total finish cost 20%.

Manufacturing Engineer/Advanced Engineering Group (1996-1998) assigned to Advanced engineering group to implement cost reductions and process improvements on the OEM air conditioner clutch for the GM Saturn cars.

Developed new rotor and pulley stampings resulting in a 10% decrease in cost.

Redesigned cell layouts and made modifications to automatic assembly equipment improving process efficiency and product flow.

Made process improvements on an Eaton/Mercedes Benz supercharger clutch.

Manufacturing Engineer/Industrial Products (1989-1996) responsible for the introduction of new electro-mechanical brakes and clutches for the industrial market. This included the creation of new routings and process documentation, the appropriation of capital equipment, plant layouts, cost/time estimates and CNC programming. In 1995 FY, appropriated $1.1 million for the purchase of nine CNC lathes and machining centers with an average ROI of 28%. In 1994, introduced Warner’s first dedicated CNC manufacturing cell for the production of clutch drive hubs resulting in a reduction of lead time and improving product flow.

PACIFIC SCIENTIFIC, Rockford, Illinois 1988-1989

Manufacturer of stepper and DC motors.

Manufacturing Engineer responsible for cost justifications for production tooling, routing creation, time standards and process documentation. Also involved with product design improvements, cost reductions, and methods improvements for the manufacture of large stepper motors.

TEXTRON FUEL SYSTEMS DIVISION, Harvard, Illinois 1985-1988

Manufacturer of jet engine fuel injectors.

Senior Process Engineer in charge of creating routings, process drawings and designing dedicated tooling for the manufacture of aircraft fuel injection components made from high temperature alloys. Job scope also involved cost estimation, machine justification and process analysis with emphasis on cost reduction.

WOODWARD GOVERNOR CO., Rockford, Illinois 1975-1985

Manufacturer of jet engine fuel controls.

Manufacturing Engineer (1979-1985) responsible for routings, processing and tool requisition for aircraft engine control components used on General Electric, Rolls Royce and Airesearch jet engines. Also served on the company’s Value Analysis committee.

Value Analysis Engineer (1978-1979) accountable for analysis and design work for General Electric’s “Project 80” jet engine cost reduction program. This project yielded an average savings of over 25% on fuel control components.

Manufacturing Research and Development Engineer (1976-1978) for manufacturing processes including the development of a new patented carbide coating for hydraulic valves, the brazing of aluminum laminations and the development of “creep feed” grinding.

CNC Programmer (1975-1976) for vertical machining centers and developing tooling for components made of stainless steel and aluminum.

CERTIFICATIONS AND AWARDS

Society of Manufacturing Engineers Certificate #2072213

U.S. Patents #6,364,084 & 6,557,236

COMPUTER SKILLS: Excel, Siemens NX Ideas CAD, AutoCad LT, Encode CAM+-, ManManX

WORK EXPERIENCES

BAKER MANUFACTURING

*Managed all manufacturing engineering projects for four facilities.

*Appropriated two new CNC vertical machining centers and two new CNC lathes to update machine shop for an average cost reduction of 20% at Bakers Evansville facility.

*Appropriated and programmed a new CNC machining center, designed new fixtures and created a new plant layout to replace obsolete equipment at Bakers Bechtelsville, PA facility.

*Designed over 40 fixtures for CNC machining, product testing, assembly and finishing.

WARNER ELECTRIC

*Appropriated $600K with 45% ROI to implement integrated assembly and machining cell for 8” thru 15” diameter magnet shells.

* Insourced previously purchased components for an annual savings of $600K+.

* Led effort to reduce noise on a compressor armature for Korean automotive manufacturer and was awarded two U.S. patents and an OEM contract.

* Led cost reduction team to improve margin and turnaround for Warner’s aftermarket compressor clutch product line. This change utilized an Asia sourced forged rotor blank and field and reduced cost an average of 18% and turnaround from 4 weeks to 1 week.

* Created numerous plant layouts on CAD for consolidation of Warner’s Roscoe facility into their South Beloit facility.

* Wrote specifications and appropriation for new Speedfam grinder, wash tank and automatic riveter to implement new patent for Korean customer.

* Designed and prototyped new cost-reduced clutch for automatic doors on Chrysler vans.

* Led cost reduction project to replace pulleys machined from tubing to stamped blanks.

* Wrote specifications and appropriated custom rotary TIG welder for aftermarket field shells. This change reduced costs by over 25%.

* Created new tooling and did extensive testing and maintenance on CO2 laser welder.

* Appropriated 4 new CNC lathes and 2 vertical CNC machining centers worth $1.2M to be used in Warner’s first dedicated machining cells.

* Did extensive testing and research into improving Warner’s spot, MIG, TIG and laser welding capability.

FUEL SYSTEMS TEXTRON

* Designed multiple-position tombstone fixturing for fuel injector components used on F-16 fighters and machined on Maho horizontal machining center.

* Appropriated and implemented new 32mm Citizen CNC Swiss screw machine with live tooling to machine numerous aircraft fuel injector components.

* Did value analysis work, created routings, process drawings and tooling for new fuel injector for Boeing 737-300.

* Designed, appropriated and made tooling for new dynetic flow deburring machine for jet engine spray nozzle components.

* Made tooling and process changes to reduce cost of milling and gun drilling fuel injectors for Pratt & Whitney jet engines used on Boeing 727/737’s.

* Appropriated and implemented new Bryant hole grinder used to grind valves to close tolerances for General Electric CFM56 turbofan engines.

WOODWARD GOVERNOR COMPANY

* Value analysis team member simplifying the design and reducing the cost of the fuel control for the General Electric engine used on the B-1 bomber.

* Design review work and process development on new components for fuel control for air launched cruise missiles.

* Development team member for a new type of casting using machined aluminum laminations instead of cores.

* Extensive development and prototyping for the creation of a new carbide brazed coating for the I.D. of hydraulic spool valves.

* Worked on improving the quality of thermo sprayed carbide coatings for the O.D. of high pressure/high flow hydraulic valve spools.

* Wrote specifications and appropriation for the first “creep feed” grinder manufactured by Gallmeyer & Livingston for use on slotting jet engine fuel control arms.

* Development work on the use of Ion Nitriding, electroless nickel and chrome for improving the wear characteristics of jet engine control components.

* Wrote specifications and implemented Woodward's first electro-deburring machine.

* Made hundreds of routings, process drawings, CNC programs and fixture drawings for the production of components for General Electric, Airesearch and Rolls Royce jet engines used on Douglas DC-10, A-10 attack aircraft, F4 Phantom, air launched cruise missiles, B-1 bomber, Stealth bomber.

Extensive experience with the following manufacturing processes:

Machining: Drilling, gun drilling, reaming, boring, milling, tapping, surface grinding, centerless grinding, O.D. grinding, creep feed grinding, I.D. grinding, double disc grinding, turning, broaching, shaping, hobbing.

Welding and brazing: CO2 laser, TIG, MIG, resistance, inertia, vacuum brazing, hydrogen brazing, induction brazing.

Finishing: Vibratory finishing, dynetic deburring, thermal deburring, electro deburring.

Assembly: Conventional and orbital riveting, ultrasonic welding, pick & place robotics.

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