Quality Assurance Maintenance
Resume:
Christopher Harkai
Qualifications Summary:
Twenty years of experience in a manufacturing plant.
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Twelve years painting plastic parts and 4 years of spray PU and open pour foam utilizing ABB 5402, ABB 5400, Staubli
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RX130, Fanuc M-2000IB, M-20IB, M-16IB, P50, P200, P500 robots and Motoman HP-20.
Twelve years supervisory & engineering experience in a union environment responsible for 30 – 80 employees.
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Automotive Specific Systems including: SAP, SFR, OHSIM and CMMS (IMS5/IMS7)
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Experience with Ford Payroll and Maintenance Systems such as TWOS, MAXIMO and e-Time.
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Knowledge of Ford and General Motors Exterior and Interior Quality Standards.
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Color experience using X-Rite, MacBeth Light Booths and BYK Equipment.
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Defect Analaysis Experience: Dirt, Craters, Sags, Mottle, Splays and Part-Substrate.
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Casting processes and materials management for a tier I automotive suppliers including, but not limited to:
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! Robotic open and closed pour poly foam operations (FRIMO and HENNECKE)
! FRIMO (STAUBLI) Robotic Wet Score Machine
! GFM Automatic Laser and Ultrasonic Score Machine
! Door, IP Rotary and Trim Fixtures
! Spray PU door, IP systems
! Molding operations utilizing 3250T UBE presses
! Experience with resins such as TPO, TEO, PC/ABS, Dylark, Spray PU and others
Factory Automation Suite (FAS) & Rockware Software.
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Superb comprehension of fluid dynamics using FLUENT flow analysis software.
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Thorough knowledge of pump mechanics and the ability to rebuild small and medium sized industrial pumps from
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replacing o-rings, packings, ball check valves, fluid seals, bushings, and shafts.
Experience using (backflushing, nozzle cleaning/replacement, and membrane replacement) on a five stage HALO RO
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(180 gpm) part washer system. We used this system in the paint booth for rinsing final stage parts.
Excellent knowledge of maintenance on robot systems, conveyors & their various components.
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Complete knowledge of 1K and 2K, prime, monocoat and base/clear paint systems.
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Experience with paint vendors such as PPG, BASF, Red Spot, Rohm & Haas/Nippon, Dupont and others.
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Solid knowledge of paint testing, including chemistry and paint kitchen knowledge.
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Secondary tooling design including paint fixtures for both current and upcoming product.
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Excellent problem solver and able to make decisions quickly under pressure& adaptable to a variety of situations.
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Trained in lean manufacturing utilizing both the six sigma model and kaizen.
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Identifying new process methods that improve production yield and cut excess scrap.
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System Optimization, Implementation and follow up for maximum cost savings.
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Complete knowledge of quality specifications and rejection criteria as it pertaining to painted parts.
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Thorough knowledge of documentation for TS-16949 Quality Procedures, and PPAP process, Control Plans, FMEA’s
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and Process Analysis.
Safety procedures involving volatile chemicals, conveyor systems and robotic machinery.
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Mastery of all robotic programming using Robview and Paintworks Pro 2.0.
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Programming Fanuc and ABB controllers for various applications.
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Basic programming in Unix, Linux, and Visual C++.
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Engineering design software knowledge of CATIA, Pro-Engineering, CFX, and IDEAS.
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Excellent PC skills including Microsoft Office Suite with versatility on either a Windows or Mac.
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Accomplishments:
Supervise multiple operations (often concurrently): Spray 1, Spray 2, Spray3, D258 RIM-Trim,East Molding Press.
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Improving conveyor speed from 9 ft/minute to 17 ft/minute, achieving a 47% increase.
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New carrier configuration implemented from 750 parts per day to 4500 parts per day, achieving 600% increase.
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Switched ad-pro from single head non-electrostatic to dual head electrostatic increasing transfer efficiency by 30%.
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Incorporated two additional robots to base and ad-pro to add additional programming flexibility.
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Added new mica booth with four robots to paint monocoat and tricoat with the possibility usage as a degrade.
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Creative usage of “paint robbers” to eliminate tip drips and reduce scrap.
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Original throughput 75-80%, currently running 90-95% and still improving.
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Dirt rejection rate was originally 6-8%, currently at 0.3-1.6% and still improving.
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Downtime rate was originally 10-15%, currently at 4-6%, and still improving.
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Automated robotic dry ice blast tool cleaning, which reduced our tool maintenance overtime by over 30%.
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Auto-quip 1.5cc per rev disposable gear pump to a rebuildable bar mag DLC GP series 3cc per rev gear pump for an annual
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savings of $73,800.
Flat Rock, Michigan 48134 cell 734-***-**** ********@*****.***
Christopher Harkai
Professional Experience:
August 2012 – Present
Faurecia, Saline, Michigan
Process Engineering Supervisor, Spray PU and Paint Systems
• Total Productive Maintenance Trainer (TRM)
• Trainer for new Engineers
• New Equipment Implementation
• Troubleshoot paint spray systems
• Trouble shoot open pour PU and foam systems
• Efficiency and cost analysis
• Vendor Interface for new and improved products and processes
MSX International (Plant changed hands in 2012 as Faurecia purchased the ACH facility and I was hired direct)
Production Supervisor/Process Engineer, Automotive Component Holdings Plant (ACH) March 2010 – August 2012
• Spray 1, 2 & 3
• D258 Door Rotary And D258 Floor tools (RIM-TRIM)
• East Molding Press Area
• D258 Door, Console and IP Assembly Area
• 22X/228 Door, Console and IP Assembly Area
• Trainer for new Supervisors & Engineers
NYX International, Inc., Livonia, Michigan
Paint Engineering Manager January 2009 – February 2010
! Set-Up and Maintenance of two complete paint systems
! Interior PC/ABS & ABS
! Directing and programming robot process configurations for continuous improvement
! Inspection and maintenance of equipment for maximum efficiency
! Vendor interface for new and improved products and processes
! Troubleshooting and crisis management
Norplas Industries/Magna International, Northwood, Ohio
Process Engineer June 2008 – October 2008
! Paint Operations Management (due to budget cut salaried lay-offs)
! Exterior TPO
! Directing and programming robot process configurations for continuous improvement
! Inspection and maintenance of equipment for maximum efficiency
! Quality assurance and documentation
! Vendor interface for new and improved products and processes
Plastech Engineered Products, Inc., Romulus, Michigan
Process Engineering Supervisor April 2001 – June 2008
! Exterior TPO/ Paint Operations Management (Out of Business/Bankruptcy 2008)
! Directing and programming robot process configurations for continuous improvement
! Inspection and maintenance of equipment for maximum efficiency
! Oversees forty manufacturing personnel, training and development of team members & reviews
! Quality assurance and documentation
! Vendor interface for new and improved products and processes
Johnson Controls, Taylor, MI
Production Supervisor March 1994 – December 2000
! Lead manufacturing personnel with production and process optimization projects
! Directed lean management and JIT quality initiatives for customer quality excellence incentives
! Training and development of personnel, encompassing process operations, quality control,
performance reviews & career advancement initiatives in accordance to the company’s vision
Education:
Washtenaw Community College
Course of Study: CAD Design in UNIX environment w/ Pro-E and Catia
Flat Rock, Michigan 48134 cell 734-***-**** ********@*****.***
Christopher Harkai
Belleville High School - 1990 Graduate
Flat Rock, Michigan 48134 cell 734-***-**** ********@*****.***
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