Manufacturing Engineer

614-***-**** Maumee, OH Carl

Boyd ******@*******.***

SUMMARY of HANDS-ON MANUFACTURING SKILLS

Experience: 25 plus years in manufacturing, supporting domestic and

foreign markets.

EXTENSIVE MANUFACTURING EXPERIENCE

Program Management

Skills - Lean Manufacturing, New Product Introduction, Kaizen, 5s's, 5/6-

W's, PMP, APQP, PPAP, DCP,PSO, Gage R&R, ECR, BOM, DOE, Kanban, SPC, CIP,

JIT, Poka-Yoke, Auto-Cad, ISO/QS-9000, Reverse Engineering,GMP

Process Trouble Shooting

Skills - Lean Manufacturing, PMP, 5S's, 5-6 W's, Kaizen, Poka-Yoke, Root

Cause/Corrective Action, 5-8 D's, CIP, TPM, ECR, FEMA, Equipment

Reliability, Auto-Cad, Reconstructive Destructive testing

Process CIP

Skills - PMP, QCDSM, DFM/A, SMED, BOM, 5S's, Root Cause/Corrective Action,

TQM, Poka-Yoke, Zero Defects, RFQ, SPC, JIT, Auto-Cad, Supplier Auditing,

Equipment Validation, Reverse Engineering, PSO

CHRONOLOGY of PROFESSIONAL EXPERIENCE

Martinrea International Inc, Hopkinsville, KY

2012-2013

Tier one Automotive Supplier

Manufacturing Engineer

. CIP - Stabilize Equipment, Processes and Documentations to establish

and maintain "QCDSM"

Faurecia - Columbus, IN

2011-2012

Automotive & Commercial Exhaust systems.

Manufacturing Engineer

. CIP - Using the tools of Lean Mfg equipment, I stabilized the

equipment to achieve OEE (Operating Equipment Efficiency).

Productivity increased from 500units /day to 500 units /Shift. And

reducing scrap from 14% to .2%

PPG -Circleville, Ohio, Automotive under-coatings

2010-2011

Project Engineer

. Project scope consisted of Designing, Purchase and install new

components to refurbish and upgrade

five 14,000 Gallon liquid storage tanks (Vertical Silos) to meet API

Standards.

CIP - Redesign & Overhaul Chemical Reactors to decrease Batch process time

from 12 to 9 hours

FRANKE Beverage Systems, Ruston, LA Manufacturer of aluminum beer kegs

2008-2010

Manager of Maintenance & Tooling

. Managed the departments of Maintenance and Tooling for new plant Start-

up

. Maximize equipment reliability (OEE) to increase product quality,

capacity throughput and Safety.

WORTHINGTON INDUSTRIES, Columbus, Ohio

2002-

2008

Toll Processor of Steel, Tier One automotive supplier, manufacturer of

Pressure Vessels and Office building materials

Corporate Process Engineer Manager for CIP

. Commodity manager for purchasing MRO supplies, Capital Equipment and

Contractors using RFX process

. Department engineer providing technical support or the Commodity Group

. Supporting plants, both Domestic and Foreign in resolving production

issues by defining Root Cause,

. CPI - Individual project cost savings varied from $10-K to $1.7-

million.

. Purchase Capital Equipment and managed Hands On-Site, installations

for CIPs.

. Performed Supplier audits to confirm Bid Selection regarding

Manufacturing Compatibility and Product Conformance.

US MANUFACTURING, Fraser, Michigan

2001-2002

Tier one and two supplier manufacturer of Powertrain for SUV's and Pickups.

Corporate Program Launch Manager &/ Project Manager

. Managed 4 "launch programs" as a tier two supplier to Chrysler.

(sales value of $20-million)

. Document management control for RFX, Equipment Validation, BOM, ECR,

APQP, PPAP and PSO.

ATWOOD MOBILE PRODUCTS, Rockford, Illinois

1999-2001

Manufacturer of RV appliances, Brake Systems, Trailer hitches and 5th

wheels for RV, campers and trailers.

Manufacturing Engineer Manager

. Managed Engineering, Estimating, Maintenance and Tool & Die

departments for a stamping and an assembly plant.

. Managed Six Sigma programs to achieve Zero Defect and New Product

Introduction

. Kaizen team facilitator, resulting in an increase of 33% in cost

savings and 300% in production throughput.

. Team Manager for NPI (New Product Introduction).

614-***-**** Maumee, OH Carl

Boyd ******@*******.***

ROCKFORD PRODUCTS, Rockford, Illinois

1998-1999

Manufacturer of Tier one, automotive forged steering components and

industrial/engineered fasteners.

Manufacturing Engineer Manager

. Managed Engineering, Die repair and five production teams to increase

productivity and establish QCDSM.

. Liaison for, internal and external, customer quality issues.

METAL FORGE COMPANY, Dublin, Ohio

1986-1998

Tier One and Two supplier of Truck, SUVs' & automotive, forged steering and

suspension assemblies.

Corporate Senior Manufacturing Engineer

. Program/Project manager for seven plants in four states. Managed the

procurement and installation of Capital Equipment for CIP Projects,

incorporating RFX for EMR/MRO equipment repairs and process upgrades.

. On the road 93% resolving issues for Customers, Production, Equipment

EEO, Quality, and Suppliers.

. CIP - Modified Boiler Start-up / to be Production Ready) from 8 Hours

to 30 minutes.

. Developed new plant layouts, Plant Expansions/Relocations to existing

facilities using tools of Lean Manufacturing.

. Increased product throughput by 200% by designing, purchasing and

installing components to upgrade equipment.

. SMED - Designed and developed a process to reduce "Die change-over

time" from 8 hours to 45 minutes.

. Received the "Chairman's Award of Excellence" for Efficiency and

Production CIP Cost Savings in excess of $4MM.

. Program Manager for the Chrysler Prowler and the Ford F-150 pickup.

. Managed corporate project budget of $30 million.

Toledo Blank / Toledo Pickling and Steel Services, Toledo, Ohio

1984-1986

Manufacturer of steel and aluminum blanks/stampings for numerous industries

including Tier one automotive supplier Manufacturing Plant /Operations

Manager

. Developed policies and procedures to maximize product throughput and

quality

. Managed departments of Quality, Engineering, Maintenance, Purchasing,

Tool & Die, Production and Scheduling.

HUFFY SPORTS, Milwaukee, Wisconsin

1975-1984

Manufacturer of exercise bikes, rowing machines, weight benches, basketball

rims, poles and backboards.

Maintenance Engineering Manager

. Supervised plant maintenance with 20 directs on 3 shifts

. Developed procedures to maximize equipment reliability, increasing

throughput by an additional 35%.

EDUCATION & Certified Training

BS in Manufacturing Operations Management

BS in Business Administration

Certified Manufacturing Engineering / SME Detroit, MI

Certified Lean Mfg / SME, Detroit Michigan

Certified PMP / SME, Detroit Michigan

Manufacturing equipment/processes include:

Air compressors, Dryers, Steam Generators, Boilers, Chillers, Cooling

Towers, Swamp Coolers, HVAC, Waste Water Treatment, Batch Chemical

Processing, Ultra Filtration Systems, Kilns, Furnaces, Induction Heat

Treat, Fume Scrubbers, Bag House Filters, Clarifiers, Blenders, Blow

Molding, Ball Mills, Mechanical and Hydraulic Presses (100 to 12,000-tons),

Bridge and Hoist Cranes (3 to 30-ton), Pickling, Slitting, Cut to Length,

Blanking, Stamping, Drawing, Swaging, Bend & Coin, Extrude & Upset,

Cold/warm Forging, Cold Wire Drawing, Machining Centers, CNC, Screw

Machines, Roll Form, Roll Threading, Welding (Manual, Robotic, Resistance)

Cleaning (detergent, acid and shot blast), Plating & Painting (powder and

liquid), E-coat, Conveying Systems (mechanical, pneumatic and robotic),

Assembly Lines, Equipment automation and refurbishing, Facility upgrades,

expansions and new construction.

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