Ronald Nelson

Manufacturing Engineer

Project Manager

Hamilton, Ohio

acr3jm@r.postjobfree.com

513-***-****

SUMMARY

Innovative leader in the digital manufacturing initiative

Responsibilities as an Operational Excellence Manager:

Lead the design and implementation of initiatives or events that eliminated waste, reduce cycle time and improve business performance while establishing a sustainable model for continuous improvement.

Acted as a coach and change agent to instill the continuous improvement culture throughout the organizations.

Communicated the learning, the thought processes and the impact across organizations and value delivery system.

Trained and coached resources on Lean Principles and Six sigma methods.

Provided general

Supported the Operational Excellence departments at Pilkington Glass, Kyocera (AVX ceramic capacitors), AK Steel continuous rolling mill, GDX Automotive (rubber extrusions), Dover Corp plastics extrusions, Magnode Products (aluminum extrusions) continuous manufacturers and numerous other manufacturers eg. GE, Boeing, International Truck and Engine, BTR Automotive, Ingersoll Rand, Parker Hanafin, TRW Automotive, DOW UTC Sikorsky Helicopter, Hewlett Packard, USAF.

Profile

30 years experience in Project Management, Certified Lean Six Sigma Black Belt, Industrial Engineering with managing Six Sigma / Lean projects associated with New Product and Process Launch activities with Bachelor's Degree in Manufacturing Engineering.

Experience in highly regulated industries such as Aerospace, Medical Device, Automotive, and Electronics)

Experienced influencing others and leading change/improvements

Advanced body of knowledge of PMBOK / Project Management / Lean Six Sigma techniques with track record of implementation

Identified Improvement Projects and Initiatives to accomplished Strategic Goals

Hands-on experience in implementation of Global Best Practices in the integration of Design, Tests, DOE, Experiments / Trials in Development, Manufacturing and Assembly sectors.

DFSS, DFMA, DMADV and DMAIC methodologies training and deployments

Developed DFX, Design for Reliability, Test, Costs and Maintenance

Corrective action plans, and work around plans to meet program goals.

Tecnomatix-Teamcenter: PLM UGNXCAM, Solid Edge and CAD based CMMs PCDMIS-Pro E, Creo ProMechanica, ProManufacturing CAM, 3D Printing

Collaboration: Concurrent with Global Suppliers-Boeing 787, Club Car, International Truck and Engine New Product / Process Design using Digital Manufacturing system Autocad, FactoryFlow, FactoryCAD and virtual VizMockup to create a 3D simulation of the complete production line (TOOLING, MACHINING, ASSEMBLY SEQUENCING AND FACTORY LAYOUT) for analysis of variants for RFQ.

Proficient in Optimization-OEE-Advanced cost estimating skills which comprises; analysis process improvement.

Estimation for time standards in glass, ceramics, carbon fiber composites, plastics, rubber, automotive, truck, aircraft assembly, electro mechanical, microchips fabrication, steel making, aluminum extruding, conventional machining, cnc machining, advanced machining, ecm, edm, casting, brakes, stamping, hot joggling, bending operation steel, aluminum, titanium and other exotic materials.

Initiated Automated Capital Equipment: Robotics, PLC controlled conveyors, manipulators Projects.

Tool Development / Process Development in Mechanical Assembly, Welding, Cleaning, Cleanroom, and Test

Value Stream Mapped the Supply Chain logistics flow and sequence of processes for the Current and Future / Ideal States at numerous Facilities.

Experience in integrating the engineering development, Product Lifecycle Management, Material Distribution. Project Management, and process development team in medical devices, automotive, helicopter, aerospace, aircraft, truck and bus assemblies from concept to production, utilizing various engineering tools like OEE-Kaizens-Kanban-DFMEA/PFMEA, DOE, FEA, DVP&R, Simulations, FactoryCAD / FactoryFlow AutoCAD Plant Layout, ProModel Simulations, Site Planning, Space Planning, Operations, TOC, Demand Planning, Pull Replenishment, Supply Chain Planning, Material Handling Equipment and Inventory Management.

Experience in advanced negotiation skills which includes; Conflict resolution, Union negotiation, Gate reviews for designs, CI, Supplier Capability, Performance Audits and Qualifications. Collaboration in Plant layout proposals.

Proposal writing for marketing department.

Best in Class Manufacturing Practices, Benchmarking, Strategic Planning.

ISO13485-FDA-GMP-Validation-Verification-CAPA-TS16949

Drove deployment of Built in Quality, the reduction in quality escapes, Cost of Poor Quality (COPQ), and Materials Review Board (MRB) utilization for assigned areas of responsiblity.

Participated with the New Product Development (NPD) Engineers and the Integrated Product Delivery and Support (IPDS) process (Phase 1-5) for product transition into manufacturing including supporting the sign-off approval process.

Responsible for Phase 6 programs including identification of Manufacturing Readiness Level (MRL) gaps for assigned products and processes. 4P

Supported the Quality Management System (QMS) policies and procedures.

Factory Readiness: Developed, documented and trained step by step method sheets and work instructions for products to facilitate work cell incorporation. Ensured correct tooling and factory test equipment were available and in use. Supported all internal and regulatory audits.

Identified and implemented 8D with Root Cause Corrective Actions using processes such as Corrective Action, Preventative Action Poka-Yoke Mistake-Proofing. Participated in developing cause chains to determine real issues and cause. Suggest changes to Design Engineering regarding issues impacting product and process integrity.

Provided data for analysis and identification of capital equipment needs to address gaps in capacity, including tool creation, automation, robotics / fanuc, plc / Allen Bradley, process management and installation. Drove adherence to department Burden, Tooling and Momentum budgets.

Executed and managed projects (such as Safety, cost reduction, transitions, Supplier Quality issues, COPQ, etc.) and allocated funding for assigned areas of responsibility. Coordinated and supported efforts to align with project and factory needs. Identified and executed alternate solutions to mitigate quality and schedule risk.

Provide technical guidance to ensure improvements or achievement in: On-Time Delivery, PPM, Cycle-time Reduction, First Pass Yield, Turn Around Time, Inventory Reduction, COPQ and Safety.

Improved internal manufacturing operations including; continuous improvement statusing, budget statusing.

Coordinated improvement project planning and execution. Scorecards

Interface with Suppliers, Customers and Stakeholders

SKILLS / TOOLS

Experience in Lean applications such as: VSM, TPM, SMED, VA vs. NVA, Poka Yoke, 5S, 8D, CAPA, A3, JIT, Kaizen, Kanban, etc. Familiar with Six Sigma methodologies and applications such as: DMAIC, DFSS, BHI-DFMA, SIPOC, VOC, APQP, PPAP, D/PFMEA, MSA, GR&R, CP, SPC, GD&T, Process Mapping, Excel, Pivot tables, Macros, Access, Minitab v17, DOE, ANOVA, Chi-Square, Hypothesis Testing, Regression Analysis, Control Charts, Histograms, etc. Familiar with project management applications such as: Scope, schedule and cost as well as WBS, Gantt Charting, Minitab Quality Companion 1/2/3, SigmaFlow, PMBOK, Primavera, MsProject, MsOffice-Excel-Word-PowerPoint-Visio-Outlook-Access-SharePoint-Gap Analysis, Risk Management, and iGrafx, FactoryFLOW, VizMockup, ProModel Simulations.

Medical Devices / Aerospace:

CAPA-Corrective Action Preventive Action - RCA-Root Cause Analysis-FTA-Fault Tree Analysis-Risk Mitigation, Contingency Planning - Qualification Plans - Installation Plans-Operational Plans - Performance Plans - Validation Plans - Verification Plans - Verification of Effectiveness - Investigation - ENOVIA-Live link-Change Management Systems - SCAR - Supplier Corrective Action Reports-ISO 13485-FDA-GMP-21FR 820 483's

EDUCATION/ CERTIFICATIONS/ TRAINING

BS, Manufacturing Engineering, Lean Manufacturing Miami University, Oxford, OH, May 1986

MBA Prerequisites in Finance-Accounting-Marketing-Lean Production Operations 1985-1986

Management-Business Law-Advanced Statistics courses 1985-1986

Engineering Technology Student in NC Programming-Time Study Training, Miami University Hamilton/Middletown, OH, 1969-1975

Certified DMAIC Lean Six Sigma Black Belt/Moresteam.com/ASQ and Ohio State University November, 2004

Minitab V17, Mintab Quality Companion and Visio/Grafx purchased 2004

MsDynamics-Cloud-Excel-Access-Word-Powerpoint-Visio-Sharepoint-MSproject

Certified DFSS Six Sigma Black Belt training/Moresteam.com, 2010

Certified Primavera P3-Scheduling and Suretrak at CBA Perrysburg, Ohio 1990

Certified in MCACES Cost Estimating at Building Systems Design Atlanta, GA 1990

Certified in MOST Maynard Operations Sequencing Techniques 1994

Experienced and Certified in SAP, AS400/MOST at International Truck and Engine 1995

Extensive Plant Layout, Material Flow, Line Balancing and stopwatch Time Studies experience 1968-2014

Studied Plastic Technology Testing at Edison State Community College, Piqua, OH, 2002

Studied 40 Six Sigma Video Tapes by Dr. Mikel Harry and Greg Brue 2000

Gemba Academy Tools purchased 1998

SigmaFlow purchased 1997

Studied Toyota Production System TPS 1986-2013

Certified AutoCAD/Design 540 hours Training Butler Tech Hamilton, Ohio 1991-1992

Trained and experienced in Autocad 10 thru Autocad 2015

Certified in Pro E software license since 1996-ProJunior-PT Modeler-Pro EWildfire2000i-vs 5.0-Creo vs. 3.0

Certified UG 17-UGNX V8.0 and Mastercam 1994-2015

Familiar with Inventor-REVIT-2013-AISC-ANSI-CAE-FEA- NEINASTRAN-SOLIDWORKS-CATIA V

Certified AIAG : TS16949-QS9000-APQP-FMEA-PPAP-CP-MSA-GD&T-SPC-ePPAP

VSM-CI-KAIZENS-5S-OEE-RCA-8D-Problem Solving, DFMEA-PFMEA and Control Plans

EXPERIENCE:

Faurecia. North America Auburn Hills, MI. Sept 28 2015 to present

Supply Chain Industrial Engineer

APQP - PPAP - ePPAP - Supplier documents for GM seats

Supply Chain compliance for offshore Mexico plants.

Zimmer Orthopedics Warsaw, IN Oct 6-2014 thru Dec 20, 2014

Six Sigma Black Belt Consultant

Sr. Quality Engineer

CAPA 650 Lead for Medical Devices Manufacturer of Orthopedics Products.

Knee, hip, shoulder and trauma implants

QP-IQ-PQ-OQ-IQSRs-IR-VOI-VOE

Project Leader of contractors and direct employees for the validation, installation and qualification imlpementation of 39 PCDMIS 2014 software upgrades to control Brown and Sharpe Coordinate Measuring Machines (CMM's)

RCA-FTA-SCAR-CAPA-IR-Remediation - Risk Mitigation - Contingency Plan - VOI-VOE-DOE-FDA-GMP-GDP-Validation-Verification-Planning-Scheduling-Reporting-Trainer-Video Time Studies-TimerPro-Line Balancing-Productivity Improvement-Communications Planning

Communication Plan-ENOVIA-Management Reports-Tracking-Issues Resolution-Team Meetings-Reliability Tests-Error Proofing

Trained Resources for Installations-QP-IQ-IQSR

Gathered the right data for analysis and operations modeling for DOE

Created timeline for installations and created resources to accomplish objectives

Navistar International Truck and Engine, Springfield OH Sep 13 - Oct 13

Lean Manufacturing Specialist Lean Six Sigma Black Belt Consultant

Contributed to the team effort by Performing Supplier logistics and Sub operations observations /data collection (time studies) for all Truck Assembly.

Process Improvement applying Modapts to Balance the Assembly Line with the objective to reduce the headcount of direct employees by 50.

Introduced to Cab Trim Management a Facilities /Conveyor Equipment Project that will increase the capacity/ yield two Trucks per week for a gross revenue increase of an estimated $8 million per year for the Springfield Assembly Plant

Innficon Inc., Syracuse, NY Feb 13 - Mar 13

Lean Six Sigma Black Belt Consultant

Lean Manufacturing Initiated all the process development in Mechanical Assemble, Welding, Cleaning, Cleanroom, and Test to Process Map the Supply Chain logistics flow and sequence of Current state Value Stream Map.

Used AutoCAD 2013 layering to create the flow of material, product and production processes for Shipping, Receiving, Mechanical Assembly, Cleaning, Clean Room Assembly, Packaging and Tests.

Project management, budgeting scheduling, design and installation and maintenance of industrial automated machinery projects

Assessed the feasibility to automate with AGV, Robotics, vertical ASRS and carousels to enhance the KANBAN, Feasibility Studies

Analyzed the facility and created a future state VSM with two options.

A greenfield vs.a brownfield option.

Vendor Collaboration and Research for Automated solutions to improve SMT production yields and tool up-time through optimized process monitoring, analysis and control.

Implement Lean Manufacturing, Identified improvement opportunities with flow, transportation, and space and cycle time.

Determined cycle times to cost current state VSM

Created cost model for future state VSM

Clean Room Design concepts including multiflorous materials/ utilities, maintenance access and gases between floors

TRW, Lafayette, IN Oct 12 - Nov 12

Lean Manufacturing Engineer/ Lean Six Sigma Black Belt Consultant

Lean Manufacturing Engineer for Steering Gear Manufacturing

Tracked Supplier Collaboration/ Quality for outsourced heat treating (Inventory Management)

Introduced to Manufacturing Engineering TimerPro Video Time Studies to create standards, work instructions, line balancing and Implement Lean Manufacturing.

Worked with APQP PPAP and PFMEA teams Use planning system tools, past manufacturing experience, and academic knowledge, to address/predict all possible manufacturing/quality causes for product/process failure.

Development of process/ methodologies for VSM-current state Bottleneck at machining-grinding-hobbing-classifying heat treat and CMM tests lab workflow-pfmea-control plan-

Identified improvement opportunities in methods-CAM-TPM-OEE

Mentored-coached-trained engineers, supervisors and operators in Setup Reduction

Project Management/Tracking/Facilitation and Kaizen Leadership

Created Video Visual aids for operations, and training Quality Technicians/Coops

Floor Support for operators needs for tools, information and quality

Created GR&R training material which increased yield and reduced scrap Implemented a CNC setup reduction (SMED)= 14 minute to 2 minute grinding wheel change (applying a pre-assembled grind wheel assembly) over that eliminated bottleneck at sectors Magerle grinders and increased revenue capability by 30%. For Steering Gear Assemblies

Ford F-150 Truck Steering gear systems

Pilkington Automotive Glass, Shelbyville, IN Aug 11 - Sep 11

Lean Six Sigma Industrial Engineer

Performed Time Studies that contributed to line balancing, manpower allocation (utilization), and decreased downtime, eliminated bottlenecks and improved throughput, flow, capacity which increased yield to furnace dept. and quality by 20%.

Risk Management-Collected Data of Downtime. Performed Analysis using Paretos for problem solving system and equipment failures, OEE, preventive maintenance and Continuous improvement at pre-process flat glass production (cut, break, grind) and printing stations.

QS9000-TS16949-FMEA-APQP-PPAP-CP-SPC-MSA

AutoCAD cell layout design

Tier One-union plant-Ford Production line

Kaman Aerospace Structures, Jacksonville, FL May 11 - Jul 11

Manufacturing Process Planner-CNC Programmer-UGNX6 flat patterns from legacy adobe pdf's AutoCAD -MasterCAM, FAIR/DISCUS

Created Complete Manufacturing Process Plans in CAPP for sequencing shear-punch-stamping-roll forming-joggling-fabricating/finishing sheet metal and extrusions details used in Bell-Textron-Sikorsky Blackhawk Military helicopter cockpit assemblies.

MRP:Citrix-DISCUS (FAIR}Engineering Graphics GD&T -CAPP-MPP-TRAINED in UGNX6-CNC MasterCAM Programs for sequencing KOMOS extrusion and aluminum and steel sheet metal manufacturing, heat treating, fabrication machines.

Quality Auditing: Supplier Qualification-First Article Inspection FAI-AS9102-ITAR

Advanced DFSS Six Sigma Black Belt Training in (DFSS/DMADV/IDDOV) at Moresteam.com online 2009-2010

Global Aeronautica/ Boeing Company, North Charleston, SC Mar 08 - Nov 08

Industrial Engineer

787 Composites Fuselage Assembly Time Study Supplier (Capability) Audit resulting in Boeing's buyout of Global Aeronautica in 2008

As an Industrial Engineer/ Cost Estimator/Analyst SME team member established comprehensive accurate costs for 787 Mid/Aft fuselage assemblies joining/aligning and identified the cost impact using TimerPro's estimating database for assembl/instaalations of newl engineering changes within the hydraulics and electrical systems (WIRING) installations processes.

Utilize management tools, training and techniques to track projects focusing on critical gates for on time completion, while reducing cost and maintaining or exceeding quality standard; Primavera.

Optimized costs through effective (Concurrent Product and Process Development) CPPD, choosing suppliers, and maximized chances of getting parts correct the first time.

Experienced in managing all commercial, quality and delivery of direct material commodities such as Castings, Forgings, Assemblies and Machined Components.

Created a Time Study cost database with pivot tables and TimerPro software for composites drilling, filling (FASTENERS), joining, painting, alignment and flow handling operations.

Identified NVA/VA and identified problems (waste and defects) with drilling/filling (shop floor support) and provided data collection using TimerPro to the Lean team (AIG) Process Improvement Project.

787 Fuselage Final Assembly Integrator

First nine ship sets

CPQP International, LM Glasfiber Little Rock, AR Oct 07 - Feb 08

Composites Wind Mill Turbine Blades Manufacturing Plants

Program Management, Organization, Change Management Industrial Engineer, and Workflow design for collaboration of lean (pull scheduling) construction and installations.

CPQP Coordinated the CH2M HILL Design-Construction for two NewPlants and one modified plant site/permits-inception of construction.

Defined quality standards, cost tracking budget performance metrics (Scorecards), codes/permitting procedures, supply chain redesign (OTD).

Improved AutoCAD Plant Layout, processes, DFMEA, project tracking of tasks, costs, and on time deliveries (OTD) of HVAC, and mechanical/electrical/hydraulic and dust collection equipment installations for the manufacture of 120 ft. long carbon graphite (VaRTM) composites wind mill turbine blades.

NPI-APQP-PFMEA-PPAP-CP-AUTOCAD

Consultant to Boeing Company Everett, WA Jul 07 - Sep 07

Industrial Engineer/Supplier Capability 787 NPI

Identified and implemented improvements to Plant Layout and processes by analyzing current processes and utilizing established improvement methodologies to maximize the efficiency of equipment and personnel to support company improvement initiatives.

Analyzed changes to approved plans resulting from unplanned events.

Assessed the impact of the changes that occurred to cost, schedule, resources, and delivery.

Developed modifications to existing plans and obtained approval for plan changes.

Member of Boeing team that performed the Summit at Vought in North Charleston to audit Vought's Supplier(s) Quality Capabilities resulting in Boeing buyout of Vought

Participated in negotiations representing Fuselage LCPT to support schedule commitments and/or statement of work impacts.

Maintained Traveler Deck, LOB and Waterfall charts. Tracked all on dock dates for Partner end items and coordinated end items for expeditious delivery. Developed Statement of Work, Manufacturing Build Plans, Convergence charts and coordinated plans for traveled work (Progress tracking) from Partner/Supplier, coordinated with Change Incorporation airplane commitments focal and coordinated the BPR deck preparation, tracked schedule risk associated with respect to Global Aeronautica/Vought & Final Assembly (FAD).

AK Steel Mansfield, OH Mar 07 - Jun 07

Industrial Engineer Robotics Applications-Automation

Concepts for Lean Manufacturing, Cognex Machine Vision-ultrasound inspection automation-manipulators-sampling probe automation-Slide Gate-Chock Changes-Detailed Autocad Equipment and tooling Plant Layout Design

Stopwatch Time Studies

Project Engineering Stainless Steel Melt Shop-Caster-Finishing Mill-LMF Ergonomic Safety Process Improvements

GDX Automotive (Cerebus Holding Co.), Wabash, IN Mar 06 - Oct 06

DFLSS Lean Implementation Industrial Engineer

Value Stream Mapping, Stopwatch Time Studies and work cell designs.

Designed, specified and implemented Lean Plant Layouts for existing and new product development (robotics), new extrusion and injection molding processes for black rubber, plastic and metal bonding seals, doors and windows for vehicles.

Plant Layout for greenfield and brownfield.

Detailed Equipment installation drawings for electrical schematics, mechanical and piping for extrusion presses, ovens, calendaring, power distribution and control panels.

Weather-stripping for Toyota, Volkswagen (robotic paint station), Ford escape (new robotic assembly station), New Launch of Ford GT and improvement to capacity/production for GM, International Truck, Mazda, Chrysler, Ken worth, and Freightliner.

Improved material flow, space, line balancing and capacity 20%. AutoCAD 2006

Reduced cycle time 10%.

Reduced inventory 20%

Standardized equipment and processes.

Facilities Design: DFX-DFM-DFA-DFT

IS0-QS 9000-TS16949

NPI-APQP-PFMEA-PPAP-CP

Parker Hannifin Marysville, OH Mar 06 - Apr 06

Project Manager for a Lean Value Stream Management Project

MS Project, PowerPoint, Excel, A3 and AutoCAD.

Established Kanban (FIFO) scheduling between machining and assembly and for purchased castings, Stopwatch Time Studies

Utilized two card systems with 24 turn level and increased productivity of work center to 80%.

Created and maintained DFSS metrics (Scorecards) and tracking of Quality First Pass Yield to 96%

Reduced Cost Pieces/Labor Hour; Delivery: Customer Shortage Cell or

Supermarket Shortages; Safety, 5s+1; Downtime Charts Pareto Analyses Task List.

Total Productive Maintenance-TPM and Kaizen tools training.

Implemented these Lean Methods to reduce downtime and machine

reliability: Job Layouts-Standardized Work-Mistake Proofing-Quick

Changeover/Setup Reduction-TPM check sheets/audits.

Results were cycle time reductions of 50%.

Reduction of WIP. FIFO heat treating

Two operators running three test stands.

Improved units per person per day from 14 to 20 (43%improvement).

One piece flow, andon lights and reduced response of errors to assemblers.

GDX Automotive Wabash, IN Dec 05 - Mar 06

Lean Industrial EngineerPlant Layout

Consolidated 3 Manufacturing Plants/Installation/Moved Rubber Extrusion and Injection Molding Machines from North Carolina and Arkansas to Wabash In.

Detailed Utilities-Electrical Drops / Distribution-Mechanical-Pneumatics, Plumbing Connections and foot prints Plant Layout

Integrated Material Flow, Detailed in AutoCad

Kimball/Flexcel, Salem, IN Sep 05 - Oct 05

Black Belt Process Engineer

Lean Deployment and Implementation.

Value Stream Mapping, PFMEA, Time Studies, Line Balancing and Visual Controls

Trained operators

Applied kaizen blitzes and Kaizen events, Gemba Kaizens

Reduced to 24 (FTE) full time employees from original 30 FTE cabinet

Built and reallocated resources to create a new labor pool.

Project scope was 53 FTEs for 4 month goal for complete line at $33k/FTE.

GE Transportation Systems, Erie, PA Mar 05 - May 05

DFSS Industrial Engineer

Responsible for applying all time standards for complete Locomotive Final Assembly.

Created and revised process plans using CAPP software tool Computer Aided Process Planning

New Product Launch-Green Engine

Dover Corp. (OPW), Smithfield, NC Jan 05 - Feb 05

Cost Estimator

Multilayered plastic pipe extrusions for gas stations

Analyzed Process performance to identify wastes and recommended changes to settings to increased yield and meet OTD.

Club Car Inc. (Ingersoll-Rand) Augusta, GA Jun 04 - Nov 04

Consultant Black Belt Manufacturing Engineer/Assembly

DMAIC-Project Selection, Project Charter, Deployment, Trainer.

Six Sigma Certified Black Belt Deployment

Trained Greenbelts in DMAIC/DFSS and lead a cross-functional team.

Achieved Lean Six Sigma Black Belt Certification

Analyzed the Manufacturing and Assembly Process

Supplier Quality Management-Audit-Controls-Containment-Defect Tracking/Elimination

Global China Sourcing and Manufacturing Integration (Manufacturing Build Plan) of New Products/Processes

CHANGE MANAGEMENT: ECN-ECR-BOM accuracy-Lotus Notes-Pro E Wildfire 2.0-ProIntralink

DFSS-Product Development-DFMEA-PFMEA-Developed Next Generation Gen-2 Accelerator Pedal.Group Assembly

Trained Product Engineer team in DFM-DFA-DFTest methodologies

Demand Flow Technology-Lean welding cell design (golf carts).

Reduced COPQ $500,000 per year and increased Net Revenue $2,000,000 per year.

Improved performance of gas golf carts speed to (> 12 mph).

Improved Customer (Golf Courses) Satisfaction

Kerotest Manufacturing Co., Marksville LA Jun 03 - Sep 03

Lean Manufacturing Consultant/ Change Agent

Consulted to General Manager the current state, future state and implementation plan.

Developed Lean Transformation training material for presentations in TPM .

Manufacturing Audit

Continuous Improvement.

Created VSM Maps for materials flow internal logistics.

Tolerance Analysis Variance reduction plastic injection molding-GD&T

Reduced defects and material waste and cycle time/for Polyball Mazak Lathes

Stopwatch Time Studies

Wrote CNC G-code work instructions and wrote test procedures for plastics fusion (assembly) process standardization

Visual Work Instructions for Injection Molding and Mazatrol CNC Lathes turning plastic ball valves

Steel valves GD&T variance reduction resulting in yield improvement

Consultant to Six Sigma Pipe (Startup), Columbus, OH Dec 02 - Jun 03

Volunteer Industrial Engineer

Estimating-Personnel-Training-plastics Mold Design-Tool and Mold Qualification/Startup-Auxiliary Equipment, Plastic Pipe Extruders Specifications-Plant Site and coordinating training resources Government grants with Edison State Community College in Piqua Ohio and Society of Plastics Engineers (SPE) Subject Matter Experts (trainers).

International Truck & Engine Corp. Sidney, OH Jan 02 - Nov 02

Corporate Team Consultant Six Sigma Quality Development Engineer-Process-Pre-Delivery Inspection Auditor

VSM-Process Mapping-Process capability to achieve 1.33 cpk for 30 Key Process Indicators (KPI's) DFSS-DMADV-Sustaining Gains-DMAIC improvement.

Collaborated with Design and Manufacturing / Quality teams for to reduce costs-CAPA-RCA preventative/corrective action-variation control-defect tracking-auditing-systems/database development-process flow -value stream mapping-pareto analysisstructured problem solving using 8d warranty reduction RDAP -reliability engineering lean manufacturing-work instructions-visual aids-5's-QS 9000

Applied PFMEA Controls to sustain Six Sigma gains

Multi-plant-technology transfer-standardize

Lead Kaizens, and Six Sigma Projects 25% costs savings

$900 Million Project =15% SAVINGS during 5 year 1998-2002

Exel Logistics Westerville, Columbus, OH Jan 02 - Feb 02

Lean Supply Chain Industrial Engineer

Assessed and Designed Autocad Plant Layouts/Lean Transformation for US Xerox distribution centers and warehouses east of Mississippi River

Designed conveyors and pallet rack systems

Integrated Red Prairie Systems

Labor standards for picking and packing

Material flow design

Consultant at GKN Aerospace Alabama Tallassee, AL Mar 01 - Jul 01

Lean Industrial Engineer Autocad Plant Layout

Quality: VSM-Visio Process Mapping-Applied Flow-Pull system

Visual Factory Reports (Scorecards) for Cost-Schedule-Quality

Applied TOC for constraint reduction-flow improvement-NDT-Ultrasonic Flow Stopwatch Time Studies

Six Sigma Line Balancing-Video training layup-preparing processes.

Wrote work instructions for thermoset and thermoplastic resins, and Standard reinforcement fibers such as carbon, fiberglass, Kevlar, Spectra, and others.

Developed and lead multidiscipline teams to create NDT inspection methods and plans for oven curing/autoclaves production flow, throughput and on time delivery/quality improvement, i.e.; ultrasound-system with squirter and bubbler techniques, ultrasound-immersion system. MRB team.

Eliminated bottleneck at NDT to assure OTD of Boeing Blocker Doors (Aircraft Composites) Structures)-GE-Airbus-Sikorsky-Pratt Whitney.

International Truck and Engine Jan 98 - Oct 00

Springfield / Sidney, OH Garland, TX Chatham, Ontario, CA

Corporate Manufacturing Excellence Team Member Plant Layout SME

Lean Manufacturing Engineer, Materials and Assembly Departments

Six Sigma Trainer

New Product/Process Development/Introduction-Next Generation Vehicle Integrated Product/Process Development Corporate Strategy-WCM-

Methods and Tooling Improvement for Chassis-Interior Trim-Powertrain-Transmission-Paint-Door Assembly-Wire Harness

Lean Logistics Flow Materials Management Inventory

Responsible for Conceptual and detailed Plant Layouts (AutoCad) and in-plant logistics simulations with Quest/Factory Flow-Line Balancing/MOST-3d VisMockup for Assembly Simulation Modeling

Lean Six Sigma Facilitator

Introduced and Implemented Solid Edge for Tool Designers

Trainer-coach

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