Joseph S. Andreas

*** ******** **

Dayton, TN ***21

423-***-****

acplj1@r.postjobfree.com

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

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