Engineer Manufacturing
Resume:
Michael Wayne Long
Phillipsburg, NJ 08865 *********@*****.***
My expertise is in manufacturing processes. My skills allow me to determine methods to manufacture product, improve existing techniques, and provide design feedback for future items. To help provide some idea of my background I will describe some of my work experiences at GDLS – Force Protection. I functioned as the Senior Fabrication Manufacturing Engineering on the Buffalo Program. This program was identified as a US Program of Record. My job responsibility was to increase production capacity, quality and delivery. This was accomplished by a combination of several techniques.
• A Critical to Quality (CTQ) analysis was used with the manufacturing team (including Failure Mode Effects Analysis) to defined Cause and Effects of High Risk items to the assembly process. I then developed in process measurements as part of a Control Plan (CP) and associated build record. The CP was used to ensure that these variables of the process where statistically in control. Some of these qualitative measurements where controlled at a tighter level than defined by the design. Providing a capability improvement to minimize affects on customers.
• Participation in design reviews of drawings, models and specifications were performed. These reviews provided feedback for Design for Manufacturing and clarification of documentation.
• Quality issues were addressed by performing containment and utilizing various problem solving techniques: o Engineering Change Requests (ECR's) to improve Design. o Nonconforming Material Reports (NMR's) for supplier quality issues were performed. o Stop gap approaches were developed with the use of in process checks and tooling.
• Process documentation was generated to clearly identify required fabrication procedures. This documentation provided necessary links to published design requirements, quality requirements, as well as appropriate Welding Procedure Specifications or Procedure Qualification Records.
• Implemented appropriate “As Fit” conditions defined by AWS D.1.1 for final product.
• Developed processing techniques to control variability by utilizing back step, weld sequence, back bow, and heat/cool cycles. These processes were verified using process Reliability and Repeatability data collection, before implementation.
• Managed multiple projects to develop unique tooling, tooling upgrades, and off-the-shelf equipment. Tooling requirements were determined based on safety, quality, and production.
• Reviewed Manufacturing Bill of Material (mBOM) to ensure accuracy. This was to support the planning and purchasing activities to provide Just In Time (JIT) part delivery. Additional mBOM's structure was implemented to generate work orders that listed parts usage in order. Thus supporting the use as an aid in communicating the 5S step of standardizing the work process. The results also helped develop workstation improvements of material flow and line balancing.
• Engineering efficiency was improved by writing Macros to perform functions that aid in data analysis. These include; run charts, R-Bar X-Bar charts, time studies, stock status, and process sheets.
• Developed methodology for tracking “Heat Numbers” of critical components for capsule production that became best in class process for plant.
Although, these items were limited to fabrication, I have used similar techniques to improve other processes such as grinding, machining, and assembly. I have spent much of my career as a liaison between Product Design, Manufacturing Engineer, Production Group, and even IT Development. Thank you for your consideration,
Michael Long
Michael Wayne Long
819 Wilbur Avenue, Phillipsburg NJ 08865 *********@*****.***
SUMMARY
A Mechanical Engineer with extensive experience in manufacturing. Known for creative problem solving, design for manufacturing, and managing projects related to software development, purchasing equipment, and overhauling machinery.
Creative Problem Solving Liaison Skills Design for Manufacturing Reviews Lean Manufacturing Six Sigma BB (Villanova) Geometric Dimensioning and Tolerancing Statistical Process Control ISO / QOS Leadership, Mentoring, and Training Manufacturing skills cross the industries of automotive, defense, aircraft, medical, and ceramic.
Lead manufacturing activity to achieve (Buffalo) Program of Record DOD status by using manufacturing engineering methods to defining/clarifying process, addressing quality issues, develop traceability techniques, performing drawing reviews, developing accurate bills of material, and generating engineering change requests.
Streamlined Ford manufacturing feasibility review process from a manual to a web based application utilizing DMAIC techniques to lead team in defining requirements and develop application. Trained powertrain design and manufacturing locations during roll-out of process. The approach received the 2001 Excellence Award for Manufacturing.
Member of the Ford Engineering CAD and Drafting Standards (FECDS) Committee - participated on this corporate team as a technical expert related to manufacturing. Membership on this international standards committee was by committee nomination only.
TECHNICAL SUMMARY
Manufacturing Skills: Welding, Grinding, Assembly, Machining, Casting, Forming Quality Techniques: Control Plan, Non-Conforming Material, DMAIC, Reliability / Maintainability Lean Manufacturing: Failure Mode and Effects Analysis, 5S, Visual Factory, Value Stream, Just In Time, Application Skills: MS Office (Excel, Word, Power Point, Access), Project. Programming Skills: DOS, VBA, HTML, ColdFusion, PHP, LISP, G-Code, M-Code. CAD: AutoCAD,
CAD Feas. review: Solidworks, IDEAs, Inventor, CREO, CADDS PROFESSIONAL EXPERIENCE
PRECISION CASTPARTS CORP - RATHGIBSON LLC – North Branch, NJ 2013 - 2015 Process Engineer
Responsible for process improvement of tube manufacturing including; documentation, tooling, and problem solving.
Participated in PCC Technical Development Program.
Developed tooling and process improvements for improved efficiency.
Developed Access based tool tracking system.
GENERAL DYNAMICS LAND SYSTEMS – FORCE PROTECTION, Ladson, SC 2006 - 2013 Sr. Manufacturing Fabrication Engineer
Process owner of MRAP vehicle (Buffalo) including; documentation, development, and problem solving.
Increased monthly production from 5 to 15 vehicles by implementing standardized approaches.
Improved production rate and quality by developing tooling and techniques to manage tools.
Minimized non-conformances and variability by utilizing problem solving and statistical analysis techniques. Michael Long Page Two
FORD MOTOR COMPANY, Westland, MI 1993 - 2006
Central Mfg. Engineer Powertrain Operations
Developed and standardized processes and techniques to aid 32 manufacturing facilities during production launch and daily support.
Coordinated cross functional team in the development of Electronic Manufacturing Exchange (eMIX) a method of sharing information between engineering, plants, and equipment suppliers during program launch.
Led team to develop an external company and plant best practice review database.
Developed/improved VBA macros for excel based files, which included but not limited to file check of supplier documentation submissions, data analysis, and time study (MODAPTS)
Led cross functional team and managed projects for standardizing several Plant Floor Systems (PFS) applications. These applications where used to set up the applications and infrastructure required for successful program launch. The Document Management System (DMS) and the Tool Management System (TMS) were multimillion dollar projects.
Plant assignments were intended to provide for experience in engineering development.
Initiated and lead cross functional/multisite team which developed and maintained PTO AutoCAD Standards for Machinery, Facility, And Tooling Drawings. This standard was incorporated into FECDS, described previously.
Environmental Engineer (Dearborn Engine Plant) (3 mo)
Researched and presented results of the chemical treatment in waste water process.
Monitored plant water usage and facilitated waste minimization processes.
Camshaft Process Engineer (Dearborn Engine Plant) (8 mo)
Generated and maintained process documentation and quality records for department.
Addressed production capability by managing project to overhaul lobe grinders.
Bimetal Crank Bore Study (Romeo Engine Plant) (2 mo)
Collected and analyzed data to determine source of process variations. Documented a method to chart a process which was in control, but constantly degrading. Stortz Instrument Company, St. Louis, MO 08/1991 - 12/1991 and 05/1992 - 08/1992 CO-OP Mfg. Engineer (8 months total)
Supported processes for manufacturing medical microscopes for Ears, Nose Throat (ENT).
Improving production by designing optical alignment gauge and paint plugs.
developed a robust process for aligning lamp drawers which addressed natural variation in square tubing. GE Aircraft Engine Maintenance, Strother KS 01/1990 - 08/1990 and 01/1991 - 05/1991 CO-OP Mfg. Engineer (9 months total)
Supporting processes related to; plant floor inspection, teardown and maintenance of CFM56 turbine engines.
Improved quality and efficiency by developing a process for selecting turbine nozzles for engine rebuilds.
Improved component tracking and reporting by writing Lotus macros.
Participated on team to updating engine repair manuals. EDUCATION
University of Missouri Rolla Mechanical Engineering BS/ME (3.8 / 4.0) Southeast MO State University Electronics Technology and Pre-Engineering. (direct transfer to UMR)
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