Manufacturing Engineer/Process Engineer
Resume:
CHUCK GUASTELLA, CSSGB
Cottage Grove, WI 53527
608-***-**** **************@*****.***
BACKGROUND SUMMARY
Accomplished, results oriented Manufacturing Engineer with extensive
experience working for leading designers, manufacturers and marketers of
electronic instrumentation and data acquisition systems as well as in the
industrial machining, electro-mechanical, refrigeration, industrial
controls and Injection Rubber Molding environment of the dairy farm
equipment industry.
SKILLS
Six Sigma-Lean Manufacturing Principles Certified Six Sigma Green Belt
Capability Studies (Cp & Cpk) Value Stream Mapping (VSM)
Process Optimization & Design Continuous Improvement (Kaizen)
Outsourcing-Contract Manufacturers Kanban Replenishment Systems
Design for Manufacturability (DFM) NPI (DFM) & (PFMEA)
Standardization & 5S Cell &Point-Of-Use Design
Automation Injection Rubber Molding
PROFESSIONAL EXPERIENCE
BouMatic, Madison, WI
BouMatic is a global leader in the design, manufacture and supply of the
highest quality milking systems and dairy farm equipment including milking
parlors, herd management systems, milk cooling systems, dairy hygiene
chemicals, udder healthcare products, hoof care products and dairy supplies
and dairy equipment spare parts.
Manufacturing Engineer-Automation 2010 to
Current
Leveraging my extensive background in Six Sigma and Lean Manufacturing to
identify and find both quick wins and projects that will benefit the
company through process improvement and new innovations. Utilizing my
strong analytical, planning, organizational skills to develop and
implement innovative solutions to complex manufacturing processes.
. Introduced new products to manufacturing by developing required
processes, facilitating prototypes & pilots builds, and working with
configuration engineers to ensure bills of material, product
configurations and routing standards are accurate and buildable.
. Functioned as a Change Agent, coach and leader in developing a
Continuous Improvement Mindset and a Lean culture throughout the
organization.
. Reviewed processes and implemented Engineering Change Orders (ECO) to
adhere to quality control guidelines with respect to In-House &
Supplier Non-Conformances as well as engineering specifications.
. Designed and implemented Point-Of-Use areas within work cells with
Kanban part bin replenishment systems and barcode scanning
methodologies, using JD Edwards ERP system.
. Lead cost savings efforts to identify new practices and procedures
that will reduce manufacturing costs. Utilize Six Sigma and Lean
manufacturing methodologies to drive process improvements.
. Recommended, justified and managed capital equipment projects that
improved safety, process repeatability/reliability and productivity as
well as risk mitigations for old equipment.
. Provide cost estimates for process improvements on current products
and major product changes (automation-Kanban-material replenishment
and automated work order generation-finished goods Kanban).
. Responsible for administering major capital investments and/or
provided necessary tools, fixtures, equipment and related training as
required for plant production and testing.
. Deployed Value Stream Maps (VSM) for Current State process analysis to
demonstrate waste in movement, excessive material handling and WIP,
which lead to an optimized Future State Process.
. Championed and developed finished goods Kanban Pull system, using JD
Edwards ERP system with automated work order generation when safety
stock is reached. Results included the elimination of planner, reduced
throughput time and increased On-Time delivery.
. Championed new business plan for software release and revision control
by creating a team that focused on the development of a standardized
process and SOP for software changes and the execution of the ECO
process.
. Innovation-New focus to reduce Indirect Labor and Non-Value-Added
processes within Direct Labor assembly processes by designing a labor
recording form, which resulted in cycle time reduction, reduced non-
conformances and increased profit margins.
. Utilized Six Sigma-DMAIC principles and methodologies by deploying
performance metrics and methodologies, such as, First Pass Yield, Cp &
Cpk, Pareto's Law and process standardization (SOP's) to eliminate
defects caused by Man, Machine, Method, Materials, Measurements and
Environment.
. Interfaced with Design Engineering for New Product Introduction (NPI),
Design for Manufacturability (DFM) and PFMEA analysis.
. Set up Work Center Routings in ERP system (JD Edwards).
. Created over 140 detailed SOP'S to alleviate cross-training time and
standardize processes.
SPX CORPORATION - LDS Test and Measurement, Middleton, WI
LDS Test and Measurement provides leading-edge technology in Product
Validation Solutions for use in the aerospace, defence, automotive,
machinery, electrical and electronics markets. Manufacturer of vibration
and environmental test equipment, as well as electronic instrumentation and
data acquisition systems used for problem solving applications in science
and industry.
Manufacturing Engineer 2006 to 2009
Managed and optimized existing product lines to ensure quality and
efficiency by applying Six Sigma methodologies.
Managed the transfer of the manufacturing processes of the Dimension
product to a third-party contract manufacturer in New Hampshire. Used Six
Sigma metrics to provide feedback to eliminate defects, improve quality and
reduce rework of outsourced product.
Performed on-site technical evaluation and provided solutions to improve
reliability and quality for OEM customer in Tokyo, Japan. Redesigned
modified cable using series in-line resistors which eliminated reflections
and noise.
. Justified and determined make/buy cost saving decisions for
manufacturing assemblies by soliciting price quotes from contract
manufacturers.
. Mentored and coached manufacturing and field service staff on assembly
and test processes, as well as complex schematic diagram and
troubleshooting techniques.
Cataloged SAP, ERP part number structures, routings, and B.O.M.'s for new
products.
Interfaced with Design Engineering to ensure design for manufacturability
(DFM), design for test, and design for service requirements are captured,
implemented and validated during NPI.
. Travels include: Tokyo, Japan, New Hampshire, California and
Massachusetts to perform technical evaluations, customer relations and
resolve issues.
Senior Electronic Technician 2003 to 2006
Thermo Electron, Madison, WI
Thermo Electron develops manufactures, and markets leading-edge technology
in electronic instrumentation and data acquisition systems for industrial
markets in power generation, automotive, and aerospace/military industries.
Senior Electronic Technician 1994 to
2003
NICOLET INSTRUMENT TECHNOLOGIES, Madison, WI
Nicolet Instrument Technologies develops manufactures, and markets leading-
edge technology in precision test and measurement instrumentation (digital
oscilloscopes) for industrial markets in power generation, automotive, and
aerospace/military industries.
Level 2 Electronic Technician 1987 to
1994
Level 1 Electronic Technician 1984 to
1987
EDUCATION
North Carolina State University
. Six Sigma-Green Belt: Organizational Problem Solving & Statistical
Analysis
Madison Area Technical College
. Associate in Applied Science Degree: Computer Information Systems:
Programmer/Analyst
Herzing College
. Associate in Applied Science Degree: Electronics
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