W. Robert Foster

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

Greenville. S.C. 29609

864-***-**** cell

acqjly@r.postjobfree.com

Summary

Engineer with extensive experience in manufacturing, industrial engineering and cost analysis. Excellent background in facility design and layout, workflow and budgeting. Directed process improvement projects and lean manufacturing implementation. Experienced in cost savings projects and capital equipment justifications.

Education

B.S. in Mathematics & Computer Science - University of South Carolina, Columbia, S.C.

Industrial Engineering Certification – Milliken and Company, Spartanburg, S.C. (1 year program)

Lean Manufacturing training, 5S training and World Class Manufacturing – Steel Heddle (GTP Greenville)

Ergonomic, safety and CPR certification – Milliken and Company

ISO 9001, TS 16949 and cGMP quality systems training

MS Office – Word, Excel, Access and PowerPoint; AutoCAD LT experience

Engineering – Professional Experience

Contract Manufacturing Engineer

Faurecia Automotive, Spartanburg, S.C. October 2014 – Present

Established process engineering standards for all BMW work instructions and process flows

Responsible for the successful transfer of information to new exhaust systems plant

Cataloged tooling and fixtures for relocation of equipment to Dexter, Mo.

Videotaped process builds of all product models for training and setup purposes

Gatekeeper for all drawing files, work instruction development and bills of material

Documented all packaging methods, packaging containers and product layouts

Photographed all PPAP parts for proper fit up and cataloged for new exhaust systems plant

Industrial Engineer / Process Engineer

Syncreon Automotive, Greer, S.C. March 2014 – Sept 2014

Work measurement, process, and efficiency improvements in an automotive logistics facility

Setup operator work stations for better ergonomic principles and safety

Work cell and material storage design and implementation Involved in master planning for plant expansion projects Revised plant layouts to optimize material flow and efficiency Setup warehousing system for maximum storage density and facility utilization Worked with outside contractors for all facility improvements and upgrades

Contract Industrial Engineer

Mack Molding, Inman, S.C. September 2013- December 2013

Packaging engineering, process, and efficiency improvements in an injection molding facility

Material handling and workflow streamlining, resulting in cost savings

Work cell and material storage design and implementation

Involved in master planning for plant expansion projects

Contract Industrial Engineer

Kaydon Bearings, Sumter, S.C. June 2013- September 2013

Work measurement, process, and efficiency improvements in a metal forming and assembly plant

Material handling and workflow streamlining, resulting in cost savings

Work cell and material storage design and implementation

Contract Manufacturing Engineer

Magna International, Greenville, S.C., 2012- June 2013

Work measurement, process, and efficiency improvements in an automotive stamping plant

Material handling and workflow streamlining, resulting in cost savings

Work cell and material storage design and implementation

Involved in master planning for plant expansion projects

Industrial Engineer

Steel Heddle, Greenville, S.C., 1994-2009

Managed the industrial engineering function plant wide in a metal forming and assembly plant

Handled cost requests and product cost analysis

Coordinated and implemented cost saving projects for the company saving the company over $100,000

Utilized lean manufacturing tools to save the company over $300,000 in manning and materials by reducing costs in production areas

Revised plant layouts to optimize material flow and efficiency Process improvements utilizing line balancing to eliminate bottlenecks and maximize operator performance which improved the cost per unit Involved in purchasing capital equipment and managing capital budgets Directed monthly inventory audits and summarized data Managed and directed a $7 million warehouse operation with 30,000 SKUs Packaging design and improvement, including cost savings projects

Plant Engineer General Nutrition Products, Greenville, S.C., 1986-1993

Handled complete design and construction coordination of major plant expansion, including relocation of facility in Fargo, N.D.

Consolidated 5 outside warehouses into a single entity

Managed $1 million operating budget and $1 million capital budget

Setup warehousing system for maximum storage density and material flow improvement Managed the plant engineering purchasing function and was involved in contract negotiations

Implemented cost savings projects in excess of $100,000

Sold $1 million in excess equipment for the company Improved packaging operations through streamlining the process with tooling upgrades and training methods to standardize operations and cost Determined manning requirements by utilizing lean principles and was involved in setting up operator route sheets and training Involved in wage administration as it pertained to operator skill level, workload, assignment and shift Responsible for plant process improvements and efficiency gains Involved in designing new packaging containers and returnable packaging

Industrial Engineer

Milliken and Company, Greenville, SC, 1979 – 1986 Managed cost reduction projects using classical engineering methods Work measurement and methods work resulting in reduced per unit costs Setup and managed incentive piece rate wage standards company wide Recommended and implemented new energy saving project which saved the company $250,000 Implemented methods projects that saved over $100,000 annually Involved in line balancing to maximize production and eliminate any bottlenecks which improved the total product cost Designed workplace layouts for optimum operator performance and material flow, including diagrams for training purposes Setup operator work stations for better ergonomic principles and safety Recommended returnable packaging ideas for major cost savings

Other Work Experience

Systems Director

Jeff Lynch Appliance, Greenville, SC, 2010 – 2012

Responsible for computer systems, phone system, printers, voice mail, email server, copiers and fax machines

Computer diagnosis and repair, including upgrades

Inventory management and control Installed cost savings program

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