Manager Engineer
Resume:
Resume of John Petak July *, ****
Nashville, Tennessee 37207
Professional Experience:
Summary
Operations expert with broad experience in Tier 1 automotive manufacturing with component experience in metal
stamping, welding and assembly, exhaust systems, interiors and fuel tanks. Lean practitioner with multiple years of
lean manufacturing implementation and continuous improvement activities. Experienced problem solver with multi
OEM customer exposure including BMW, Ford, Nissan, Honda, Mazda, GM, VW, Chrysler and Mercedes-Benz.
EHD Tech LLC – Brentwood, Tennessee (Mar 2014 –
Present)
• Senior Quality & Industrial Engineer working with Nissan Motor Company suppliers that need
assistance with PSW’s, Dimensional Accuracy from CCM, PPAP’s, Team Based Problem Solving
(8D & 5W 2H), Hour by Hour white boards, Capacity Planning and Overall Equipment Efficiencies (6
major losses).
• Introduced “Voice of the Customer” and Value Stream Mapping with A3 reports.
Faurecia Emissions Control Technologies – Spartanburg, SC (Oct 2012 – Nov 2013)
Faurecia Excellence System Specialist
• FES Specialist reports to the Plant Manager and liaises with Division Senior FES Specialists to ensure their
knowledge of Group Standards and best practices is developed within their assigned facility.
• Support problem solving activities for 25 welding cells including robotic welding and pipe bending processes
• Track process KPIs for continuous improvement activities
• Drive FES principles and standards throughout the plant and ensure managers apply the correct daily usage of
the FES standards through training and auditing activities
• Transfer FES knowledge and experience to plant personnel through shop floor improvement activities.
• Facilitate teamwork and problem-solving activities, lead Problem Solving Groups and workshops (5S,
Hoshin, TPM, SMED, 7 Quality Basics, Improvement Ideas, HSE)
• Ensure the proper induction of new operators via the FES Induction Training and make recommendations for
temporary recruitment as well as provide training and coaching to plant personnel.
• Participate in plant lay-out development and assist the plant using FES tools and principles to ensure
readiness for production changes.
Towerjazz Corporation - Newport Beach, CA (Electronics Industry) (Oct 2011 – Feb 2012)
Staff Senior Industrial Engineer
• Design, develop, test, and evaluate real time production dispatch algorithms.
• Formulate and apply analytical modeling and other optimizing methods for best performance metrics for
scheduling and line management, productivity, cycle time and on time delivery.
• Provide support for the capacity planning and loading of Newport Beach Fab and Probe and offshore
foundries.
• Work with other team members to ensure the capacities are clearly identified through thorough investigation and
application of traditional engineering planning models and tools.
• Identify applicable operational metrics to accurately highlight concerns related to the performance of each facility
to ensure the business objectives are either being achieved, or identify the reason why they are not.
• Perform capacity modeling through several in-house developed static models.
Resume of John Petak July 6, 2014
1212 Montgomery Avenue
Nashville, Tennessee 37207
• Support line balancing performance through dispatching and bottleneck analysis.
• Manage database of performance metrics and lot performance.
• Assist with capital budget management, tracking of the Board-agreed budget and each group’s spending as well as
the negotiation of equipment and service pricing.
• Work on project management teams to ensure the cycle time and capacity requirements are achieved through
completion of identified action plans, such as tool install and, process re-qualifications.
Exercise Lean LLC - Simpsonville, SC (self-employed) (May 2007 - Sept 2011)
Chief Excellence Consultant
• Serve as quality liaison to several suppliers.
• Hubbell Lighting: Tasked with reducing lead time to 15 days (vendors), developing quality system, improving on-
time delivery to 95%; teach principles, concepts and tools for Lean Manufacturing.
• Metromont Corporation: Value stream mapping workshops; waste reduction workshops – cycle time analysis,
cycle time diagrams, standard work charts and combination tables; visual management, daily tracking charts and
weekly summary on set-up/changeover reduction on 5 product lines; implemented 6S program.
• Kilroy Company: Trained 2 facilities (100 employees) in 5 Why and 8D Problem Solving, Hoshin workshops,
SMED, AS9002 ISO, supplying $20 million in CNC precision machined parts to GE Gas Turbine Divisions.
• GTE – Value Stream mapping workshops.
Faurecia Interior Systems - Fountain Inn, SC (Cockpit, Door Panel, Console) (Feb 2005 – May 2007)
Production Efficiency Coordinator
• Increase production efficiency by implementing 14 tools with layered audits to ensure success.
• Oversee quality processes and ensure efficiency.
• Train 450 associates in the Faurecia Excellence System; produced interior trim parts for BMW - Sport Activity
Vehicle X5, and Z4 Roadster in JIT environment.
• Conduct 14 Hoshin workshops in 10-month period, improving productivity by 15% in 2005.
• Setup flat warehouse to pick / pull 15,000 bought out parts delivering every 55 minutes milk runs with tug/train
systems to 11 assembly lines.
• Plan for Every Part (PFEP) systems deployment.
Inergy Automotive Systems - Anderson, SC (Fuel Tanks) (Jan 2000 – Jan
2005)
Manufacturing Excellence Manager
• Serve as Staff Manager responsible for all Continuous Improvement activity in $170 million fuel systems
division.
• Conduct monthly Kaizen Gemba workshop in primary and assembly product lines supplying 1.2 million fully
assembled tanks to General Motors (U Van, J Car, Corvette) and BMW (E36/7 roadster, X5 SAV and Z4
roadsters).
• Utilize extensive experience (12 years) in Toyota Production Systems Value-Stream Mapping, Kanban, 5S, TPM,
Process Mapping, Set-Up Reduction and Single-Piece Flow; trained employees in all aspects of Lean principles
and concepts.
Alfmeier Corporation - Greenville, SC (Fuel System Controls, Control Valve Assy) (June 1997 – Jan 2000)
Resume of John Petak July 6, 2014
1212 Montgomery Avenue
Nashville, Tennessee 37207
Manager Assembly and Test
• Responsible for daily performance to plan quality, cost and delivery of finished goods to worldwide automotive
customers BMW AG and US, MBUS and AG, Volkswagen and Chrysler supply fuel management system, ORVR
systems, OBD II solenoid valves, and plastic R O Valves for engine submissions.
• Facilitate successful transfer of Daimler Benz OBDII valve production from Germany to Greenville supplying 5
product versions daily to MBUSA and MBAG.
• Responsible for successful launch of BMW E53 fuel system modules and venture pump assembly, developing
process and equipment in Rottenburg, Germany.
• JIT scheduling in injection molding department on 150 tools to Kanban pull.
• Improve inventory turns to 24/yr. in molding.
• Train team leaders in molding on setup reduction with 60% improvement results on 14 molding presses.
• Successful in increasing sales from $8 million to $20 million exceeding the business plan each year and within
budgeted guidelines.
Education:
• Kent State University – 1975
BS in Industrial Engineering
• Spartanburg Technical College - 1996
Microsoft Office Products and Blue Print Reading
Training:
• TS 16949 – Internal Auditor 2014 Certification
• FMEA – Failure Effect Mode Analysis
• APQP – Advanced Quality Planning
• Statistical Process Control – 7 types of control charts both attribute and variable data
• 8-D Problem Solving – Ford’s Quality Operating System with Find & Fix Methodology
• 6 Sigma Green Belt & Black Belt training through Strang and Roth, PDCA – Plan- Do Check- Act
• A3 Report Outs
• Kanban/Pull Systems
• SMED – Single Minute Exchange of Dies
• Kaizen System
• Microsoft Word, Excel, PowerPoint, Access and Outlook (2013)
• Auto Cad
• JIT/Flow Production
• Trained Facilitator for DDI – Development Dimension International interaction management skills
Organizations:
• Institute of Industrial Engineer (IIE – Chapter 247); Revived and resurrected local chapter to Bronze, Silver then
to Gold status while serving as the Secretary, Vice President and President for 4 years total.
Resume of John Petak July 6, 2014
1212 Montgomery Avenue
Nashville, Tennessee 37207
• Member of the Association of Manufacturing Excellence (AME)
• Volunteer small business experience to Redemption Marketplace Alliance
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