Engineer Manufacturing
Resume:
DONALD A. CULL
HIGHLAND HEIGHTS, OHIO 44143
440-***-**** * ******@*********.***
Degreed Industrial/Manufacturing Engineer with a diverse background in
industrial, automotive, aerospace, and consumer products. Experienced
in all facets of manufacturing from site selection to process design,
capital equipment, tooling, and start-up. Capable of taking your new
product online or helping revamp an older product/process. Well
versed in time studies, plant layouts, tooling/fixturing, process
troubleshooting, mistake proofing, cost reduction and lean principles.
Open to positions that leverage my current experience, allow me to
grow into new areas and benefit the organization.
EMPLOYMENT
SWAGELOK COMPANY - Solon OFC - Sr. Mfg. Engineer, Lean & Industrial Eng.
Dept. (10/06-Present)
Product: Specialty valves and fittings
Responsibilities: Develop and run Lean Program for 63 cell plant. Lean
events included 5S, Standard Work, Setup reduction, Cell Design, Cedac
and Kaizen. Industrial Engineering: Time studies, Layouts, and project
assessments.
Achievements:
Developed Pull System that reduced WIP 41% and cut order processing time
from 8 to 4.75 days
Cut assembly costs by 20% and doubled output over 5 yr. period
Color Coded Lube containers - Ran PFMEA CEDAC that resolved wrong lube
issues, 20% RPN reduction (critical situation for applications such as
oxygen service)
60 Series Ball valve Flex-Cells - Developed concept, gained management
approval and worked as project team member to design and build 4
workcells that could run multiple configurations. Incorporated state of
the art advancements in testing, multiple polka-yokes, and eliminated a
multi-step manual torque process
JOHNSON CONTROLS - Oberlin Plant - Industrial/Manufacturing Engineer (2004-
2006)
Product: Econoline Van seats, delivered to Ford OHAP JIT/In-Sequence
Responsibilities: Lean Implementer, Time Studies (MODAPTS), Control
Plans, PFMEAs, Plant layouts, Equipment design/modify/repair, MP2 PM
program, Product/process troubleshooting
Achievements:
Automated Bench Seat Loader - Ergonomic improvement; automated cell
converged, placed in sequence and loaded product to conveyor;
previously operators manually carried and loaded bench seats
TECHCRAFT SEATING SYSTEMS, div. of Magna Intl. (2003-2004)
Product: Ford Escape vehicle seats. Delivered to Ford OHAP JIT/In-
Sequence
Responsibilities: New Plant Startup - Manufacturing Engineering &
Maintenance Supervisor
Responsible for equipment installation and start-up, Supervise staff of
two Maintenance Technicians, purchase, stock and inventory all spare
parts and MRO supplies for dept, MP2-PM program; Also responsible for
department budget, Safety and Ergonomic improvements, QS9000
compliance, Customer support at Ford plant as required
Achievements: Completed move-in/startup in 3 month time frame, Plant
launched on-time with no customer shutdowns or QR's, launched three
model year revisions in one year
TRV, Inc. - Manufacturing/Quality Engineer (2001-2003)
Product: CNC Machine Shop serving Aerospace and Chemical/Fluid Handling
Industries
Responsibilities: AS9100 - Certification, Procedures, Internal Auditor
Parker Gas Turbine Fuel Systems Division - Self-Release Certification,
PD1000 Supplier Quality Requirements, Lean Manufacturing
Representative
Quality - First Article and In Process Inspection, Gage Control and
Calibration (Gagetrak Software)
CNC - Machining, Programming (Gibbs Virtual CNC), CAD drawings, Labor
and Efficiency Reporting
JOHNSON CONTROLS - Strongsville Plant - Manufacturing Engineer (1995-2001)
Product: Mercury Villager/Nissan Quest Seating. Delivered to Ford OHAP
JIT/In-Sequence
Responsibilities: Tier 1 JIT - heavy emphasis on PM program, spare parts
inventory, contingency plans. Design/build/buy new machines and tools,
Methods, Ergonomics, product/process R&D
Plant Operations:
Unitrim - Three 10,000 sq. ft. Automated Carousel Systems each
incorporating 10 overhead carriers, Fanuc Robotic Spray Adhesive
System, and A-B SLC500 System Control
Simulator - Automated conveyor system converges product from three
assembly lines, places in order and loads into semi-trailer
Major Projects:
Robotic Spray Adhesive System - Cut scrap 20% and reduced equipment costs
$30K/yr. by incorporating better process controls; Material savings
$230K/yr.
Machine Shop - Developed/acquired equipment, training and supplies to
start a Machine Shop. This allowed us to prevent/minimize shutdowns,
provide better support to Production, and start building our own
machines, fixtures and tools in-house.
Custom Assembly Machines - Used my design capabilities to start designing
and building machines in-house. By doing this we were able to get
equipment that was robust, performed properly, and met cycle time and
floor space parameters. Cut new machine costs 70%.
Productivity & Ergonomics - By delivering better equipment to Production,
labor hours, lost time, Workers Comp. And medical costs were all
reduced. Plant earned JCI Gold Safety Award in 1999.
Achievements: Earned JCI Chairman's Merit Award
TRIDELTA INDUSTRIES, INC. - Manufacturing Engineer, Remote Control Division
(1990-1995)
Product: Air switches and controls for spa/pool, safety and HVAC
applications
Responsibilities: Methods, assembly times, tooling (AutoCAD), capital
equipment, and troubleshooting. Also worked as part of the Design
Engineering group on new product releases
Plant Operations: Hydraulic Presses, Riveting, Pneumatics, Ultrasonic
Plastic Welding, Wire Processing, Soldering, PCB Assembly, Adhesives,
and extensive hand assembly
Major Projects:
Plant Improvements - Revamped all equipment on shop floor
Product Design - Initiated improvements for better
functionality/assembly
Pneumatics - Initiated the use of air and air logic as low cost
automation
Route Sheets - Revised to include accurate times, sequences, methods
and costs
Ultrasonic Plastic Welding - Initiated as a fast, efficient, low cost
and nontoxic assembly method
NAMCO CONTROLS - Manufacturing Engineer, Electronic Products (1986-1990)
Product: Heavy duty Proximity and photoelectric sensors for automotive
plants
Responsibilities: Methods, routings, tooling and capital equipment.
Plant Operations:
Electronic Assembly - Surface mount and through-hole, automated and
manual.
Mechanical Assembly - Pneumatic equipment, epoxy encapsulation,
ultrasonic welding, vacuum processing, thermal/burn-in equipment, and
hand assembly.
Major Projects:
18mm Proximity Switch Redesign -Redesigned housing for strength, ease of
assembly and weld slag immunity
HazCom - Achieved compliance with Right-To-Know and SARA Title III as
Safety Coordinator
Routing Times - Cut monthly Labor Variance from 20% to 2% and provided
complete instructions
ALLEN-BRADLEY - Twinsburg, Ohio, Co-Op Production Engr. - Circuit board
assy for PLC's (1984)
MILL ROSE COMPANY- Mentor, Ohio, Draftsman - In-house machines (1979)
EDUCATION
MAYFIELD HIGH SCHOOL - College prep, Machine shop, Vocational Drafting
OHIO STATE UNIVERSITY - Columbus, Ohio, BSIE, minor in Manufacturing,
LAKELAND COMMUNITY COLLEGE - Certificate Program in Electronics, 2
courses
LORAIN COMMUNITY COLLEGE -Programmable Logic Controller classes 1 & 2
CONTINUING EDUCATION / SEMINARS - MODAPTS, SolidWorks, Plant Layout, PLC,
GDT, Flexible Fixturing, SMT, PLC Programming, Ultrasonic Welding
(Plastics), PFMEA, AS9100, GibbsCAM, GD&T, Lean Manufacturing
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