Joseph S. Andreas
Dayton, TN ***21
***********@*****.***
Diversified experience in manufacturing with an in-depth background in
design and development, manufacturing engineering, quality assurance,
management and continuous improvement. A demonstrated talent to
conceptualize and deliver improved product and methods to increase
productivity and quality while reducing costs. A proven ability to develop
and train working teams and manage highly productive personnel. Familiar
with all MicroSoft products.
Professional Experience
Product Solutions Inc. Athens, TN
Nov. 2006~Present
CMM Programmer/Supervisor
. Develop CMM programs for various products and gages. Perform layouts
as required and for yearly validation. CMM Programs include PCDMIS
and GEOMET.
. Established work instructions, one-piece flow during product sort.
Lead crew into customer facility for daily sort of product for all
shipping windows. Develop sort order and method to insure meeting
customer schedule.
Collins and Aikman Corporation Athens, TN
Nov. 2003~Oct.2006
Industrial Engineer
. Organize, direct and lead Kaizen events.
o Reduced manning on GMT201 transfer business from 4 operators to
2 operators.
o Reduced manning on GMX357 transfer business from 5 operators to
3 operators.
o Reduced square footage on GMX357 from 444 sq. ft. to 308 sq. ft.
o Improved QCO from 86 minutes to 51 minutes.
o Reduced manning on VacForm operation from 4 operators to 3
operators.
. Establish BOM, routings from time studies and product structure.
. Develop product/material flow.
. Maintain plant layout with updates from continuous improvement
activities.
Project / Lean Engineer
* Coordinate program launch activities to meet customer demand and
timing.
* Continuous updating of launch documents pertaining to issues
developing during pre-launch build.
* Coordinate incoming tooling into manufacturing system.
* Responsible for manufacturing integrity of product and troubleshooting
of assembly issues.
Lear Corporation Dayton, TN
April 1986~June 2003
Lean Manufacturing Manager / Operations Manager (temp.)
* Organize, direct and lead Six Sigma Black Belts and plant savings
projects to meet corporate/plant goals for cost savings: Total of
$4.7M in past three years versus budget of $2.7M (172% of budget).
* 'A' Pillar: reduced cycle time 24%, reduced weight 2%,
decreased st'd. dev. by 70%.
* Hinge Pillar: reduced cycle time 14%, reduced weight 1.8%,
decreased st'd. dev. by 32%.
* M Van Panel: reduced cycle time by 8%, reduced weight by 3%,
reduced st'd dev. by 43%.
* Develop training system to eliminate functional barriers and promote a
product-focused organization that teaches associates the basics of Six
Sigma techniques (Team Training): completed training for 84% of all
associates.
. Implement mistake proofing (Poke-Yoke) (defect free) concepts:
* Sensors installed to detect presence of clips (GMT800 and
PH131): no rejects since implementation.
* Curtain system for placing correct part into correct kanban
(PH131): no rejects since implementation.
* Identify which components would be best adaptable for creating a pull
system to improve lead-time: implemented in 18 components on eight
product lines.
* Define problem areas using data gathered from customers (PPM), scrap
records (internal PPM), rework issues (RTY) and Value Stream mapping:
identified projects and established teams and
champions to attack concerns in all areas. Reduced customer
PPM from 253 in 2000 to 10 by end of 2002.
* Operations Manager over Nissan product line: completed ramp-up
schedule from eight to 380 vehicles daily (15% above quoted volume).
* Day to day operations with JIT delivery (six daily shipping
windows).
* Reduced initial start-up crew from 95 associates to 71
associates on two shifts.
* Reduced scrap from $5,000+ daily to under $1,500 daily.
ACE/COMPASS Facilitator (Continuous Improvement) Dayton, TN
* Develop and coordinate Continuous Improvement concepts and lean
manufacturing techniques. Conducted kaizen training and
implementation sessions: Reduced cell square footage usage,
*
eliminated operators, removed or reduced
bending, reaching and rotating, reduced operator travel,
reduced operator lag time and improved one-piece flow.
* Implement mistake proofing (Poke-Yoke) (defect free) concepts:
* Sensors installed to detect presence of clips on 'A' pillars:
no rejects since implementation.
* Sensors installed to detect for short shots and presence of
clips on hinge pillars and sill plates (GMT800): no rejects
since implementation.
*
* Standardized work cells and operator instructions for all product
lines.
* Implemented TPM checklist for each work cell.
* Eliminate risk factors associated with ergonomics/safety hazards-
reduced Workman's Compensation claims through assembly redesign:
tilting fixtures, raising tables removing trip hazards.
* Implemented 5S (cleaning and organization) throughout the plant (Adopt-
A-Cell):
* Identified and assigned Champions for all sections of the plant.
* Assigned all Salaried personnel to 5S teams reporting to
Champions.
* Created checklist for daily, weekly, monthly activities.
Product Design and Development Engineer Union City, IN-Troy, MI
* Responsible for "Black Box" designs for mirror and trim programs-from
concept to prototype to production to service: successfully designed
and launched seven mirror and six trim programs.
* Coordinated all aspects of development: designing of components,
identifying and testing materials, approving suppliers and meeting
customer requirements for quality, timing and cost.
* Directed CAD operators on detail drawings for mirrors and other
exterior components.
* Prepared layouts, detail drawings, prototypes, gauge design, secondary
tooling, assembly line set-up, packaging design and pre-production
assemblies.
* Maintained customer contacts during production of parts: established
acceptable boundary samples, root cause problem identification and
solving and product improvement/cost savings.
* Work closely with tool shops in developing most efficient and reduced
cost tooling.
Accomplishments
Six Sigma Black Belt (Certified Nov. 8, 2000)
Co-designer of mirror design at Toyota Motors in Japan
Patent for mechanism for a remote-controlled mirror
Designing mirror assembly under budget-repeatedly
Education
Edison State College-Piqua, Ohio/A.A.S. Engineering Design
William Jennings Bryan College-Dayton, Tennessee/B.S. Business
Administration