Manufacturing Engineer

Brian Lane

**** ********** ****, **** *****, IN *6835

C: 260-***-****

**********@***.***

SUMMARY

Senior-level Manufacturing / Process Engineer with extensive experience in

the automotive industry. Championed projects and cross-functional teams

involving current tier-1 high-volume manufacturing processes, new product

launches and Service assembly lines. Strengths include manufacturing

project management, task management and delegation, organizational and

communications skills and project follow-up. Focused self-starter who

works well within a team environment or independently as required.

PROFESSIONAL EXPERIENCE

Multimatic, Butler, IN 2/14 - 6/14

(Manufactures Roll-formed Instrument panel frames, Bumpers & Support

Structures for various automotive OEM's)

Manufacturing Engineer

. Responsible for refurbishment and upgrade of automated assembly / welding

cells to include new Robots, welding power sources, bending and trimming

machinery, tooling and fixtures for current and new model Chrysler

Minivan sliding door track channels.

. Worked with Tool and Die shop in the development of a bowl-fed counting

device to deliver the correct amount of small screw nuts to an operator

for assembly that would eliminate manual counting errors and reduce cycle

time caused by tedious counting.

Tenneco, Inc., Ligonier, IN 8/13 - 2/14

(Manufactures Exhaust Systems for various automotive OEM's)

Manufacturing Engineer

. Champion of current project to significantly reduce the processing waste

of material from finished part. Potential savings of $350,000 - $400,000

per year.

. Involved in Launch of Exhaust System for 2015 Ford Heavy Duty Trucks.

. Provide daily technical support to 7 assigned departments. Work with

Process Technicians and Set-up to fix machines, tooling and fixture

issues, reduce downtime.

. Coordinate with Maintenance, Tool & Die and Controls Technicians to

repair and modify machines, tooling and fixtures that require a higher

level of technical involvement.

. Purchase Capital equipment to replace old and worn out. Currently

purchasing two new machines that will solve quality and downtime issues.

. Work closely with outside vendors and tool shops for tooling and fixtures

not able to be built in house.

. Responsible for creating, implementing and revising operator standardized

work instructions for my respective departments.

. Attend daily morning Production meetings and advise relevant issues and

information for my departments.

Ficosa North America, Berne, IN 4/05 - 7/13

(Manufactures outside Mirrors & body trim for various automotive OEM's)

Manufacturing Engineer

. Championed the move and implementation of numerous Mirror Service

assembly lines from a sister plant.

. Involved in new product launches for Chrysler and GM to include APQP and

PPAP activities, equipment acquisition, process development and

improvement, material handling and presentation, packaging, sample parts

for trial builds at customer's Plants, lab testing and validation.

. Provided on-going manufacturing support for semi-automated and manual

assembly lines and injection molding operations.

. Project champion for a large molding material cost-savings project with

an initial calculated savings of $466,000 per year. Actual savings

netted out to approximately $389,000.

. Project champion for defining and creating new procedures and

documentation requirements to enable the successful management of

internal Engineering Change processes for Ford, Chrysler and GM.

. Implemented a batch-management poke-yoke system on automated mirror test

station reducing the risk of delivering the wrong parts to the customer.

. Implemented a robotic rack storage system to store / change-out assembly

line pallets, reducing changeover downtime by 48%.

Bendix Commercial Vehicle Systems, LLC, Huntington, IN 3/01 - 10/04

(Manufactures rebuilt air compressors & braking units for heavy vehicle

braking systems)

Manufacturing Engineer

. Managed cost savings and scrap reduction projects utilizing Six Sigma

Green Belt and Lean Manufacturing methodologies resulting in reduced

scrap, downtime, and rework.

. Directed several sub-teams in the SLP (Systematic Layout Planning) of a

new 67,000 sq. ft. warehouse to include facility layout, conveyor design,

equipment quotation and procurement.

. Involved in new product launches that required completion of APQP and

PPAP related activities to include PFMEA's, Flowcharts, Control Plans,

feasibility analysis, design reviews, capability studies, SPC

requirements, Gage R&R's, APQP planning requirements, dimensional

analysis and ISIR sample parts for PPAP submission.

. Developed detailed operator / process work instructions

. Developed non-destructive test method that allowed welded components to

be put back in production resulting in continuous cost savings and scrap

reduction resulting in a savings of approximately $20,000 / year.

. Integrated new Shot-Blasting process that resulted in elimination of a

severe bottleneck that doubled throughput and reduced labor by 50%

resulting in a labor savings of approximately $26,000 / year and

increased production revenue of approximately $30,000 / year.

Wabash Technologies, Inc., Huntington, IN 12/97 - 3/01

(Manufactures electro-mechanical position sensors - ABS, camshaft,

crankshaft, etc.)

Process Development Engineer (2000 - 2001)

. Managed existing and new projects through cross-functional teams.

. Detailed design, development and implementation of manufacturing

processes for new products from conception to production. Involved in

the launch of these new products completing all APQP and PPAP

requirements to include PFMEA's Flowcharts, Control Plans, capability

studies, Gage R&R's, etc.

. Interfaced with manufacturing to address existing concerns with new

process development.

. Involved with cross-functional team on the process development /

implementation of the ABS sensor for Ford's Lynx / Puma vehicle.

Benchmark Engineer (1999 - 2000)

. Managed all Benchmarking activities and the day-to-day tasks of my

engineering technician.

. Performed reverse engineering functions and analysis to determine the

level of technical development, manufacturing flow, and cost build-up

incorporated in competitive products.

. Directed the electronic and mechanical testing on electromechanical

systems, subassemblies, and parts to perform functional analysis of

competitive products.

. Prepared competitive product bill-of-materials, assembly and process

flows, cost analysis and detailed presentations as resource for the

design and process engineering departments.

. Wrote and maintained permanent procedures for reverse engineering

analysis.

. Interfaced with IE, Purchasing, and Vendors to quote subcomponents and

manufacturing labor costs.

Process Development Engineer (1997 - 1999)

. Developed new manufacturing / process concepts, layouts and tooling and

equipment specifications.

. New product launches / redesigns of existing products, completion of APQP

and PPAP requirements.

. Provided labor, tooling, and capital investment estimates to the RFQ

process.

. Procured and validated the required process machinery and tooling.

BTR Antivibration Systems, Wabash, IN 10/9 -- 12/97

(Manufactures automotive rubber-to-metal anti-vibration components - motor

mount, body cushions, etc.)

Product Engineer

. Completed designs of new vehicle anti-vibration components for Ford,

Chrysler and GM.

. Directed engineering technician on prototype development and testing of

new designs.

. New product launches, completing all APQP activities and PPAP submission

requirements.

. Communicated directly with vendor and tool shops to ensure that

compliance of prototype component and tooling requirement were satisfied.

. Consulted with FEA engineer for failure analysis and dynamic / static

rate estimation of new product designs.

. Frequent direct customer contact involving new-design proposals and

presentations, design requirements and changes, prototype development

status, and quality issues.

. Worked with Account Executive to ensure that all of customer's needs were

met.

Cooper Engineered Products, Auburn, IN 8/93 - 10/96

(Manufactures automotive rubber-to-metal anti-vibration components - motor

mount, body cushions, etc.)

Manufacturing Engineer

. Managed engineering technicians in the validation / introduction of new

molds / assembly machines.

. Processing / pre-painting of steel stampings in preparation for molding /

final painting as required.

. Developed and updated detailed process instructions and visual aids.

. Provided additional process-support tooling and equipment to ensure

process capability and efficiency (i.e., special gages, test fixtures,

inspection devices, material handling equipment).

. Consulted with mold designers, product development engineers, machine

process design, and process engineers on revisions to mold tools,

assembly machines, and production processes.

. Designed and procured fixtures to destruct parts for failure analysis.

. Directed testing and dimensional layouts of parts.

EDUCATION

Bachelor of Science, Mechanical Engineering Technology

Quality Control Certificate

Purdue University, Fort Wayne, IN

Engineering Co-op Intern program - Dana Corporation

PROFESSIONAL DEVELOPMENT / TRAINING

* Ford Global 8D Training * Chrysler PSO (Process

Sign-Off) & PFMEA Training

* Six Sigma Green Belt Certification * Lean Manufacturing

* Project Management * AutoCAD

* Systematic Layout Planning (SLP) * Visio Flowcharting

* Ergonomics * MS Word,

Excel, PowerPoint, Project, Outlook, Lotus Notes

* 5Y Problem Solving

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