Muhammad Afzal Cheema

acr78r@r.postjobfree.com Home: 803-***-****

**** ******* ***** **** ****, SC 29732 Cell: 803-***-****

Manufacturing Engineer

Apex Tool Group – Sumter South Carolina (March 2015 –May 2015)

Started work as Manufacturing Engineer on March 9th after a week traveled to Dallas Taxes to facilitate plant closing and moving the equipment to Sumter. The equipment included turning centers, Machining centers, Heat treat, Black Oxide, Headers, Lab work, and assembly. I got to know the equipment and facilitated operators training. Came back to Sumter and worked with other Engineers to finish the training. I had a team of operators with me for training the contract job ended in May 2015.

Manufacturing Engineer

Consolidated Metco –Monroe, NC

Manufacturing Engineer / CNC programmer (2007-2014)

Launched 3 cells with 4 Lathes one Dial index drill/ tap 9 station machine and 2 robots. I was hired to launch these cells to machine Ductile Iron hubs after the successful launch of these cells I was given the responsibility for entire plant.

With full plant responsibility I started to focus on improvement in machining in the plant.

I focused on hub machining cells most critical in the plant called drive cell.

This cell had 2 operations turning and drilling turning was first operation.

Problem on turning was toll life, quality and down time.

I implemented round insert for heavy and interrupted cuts.

This improved tool life from 3 times a shift to one time in 24 hrs.

Time saving for this was 45 minutes / shift to 10 minutes / 24 hrs.

In finishing operation carbide inserts were used and the operators were changing inserts every 35 parts.

Every time inserts were changed 4 to 8 parts were scraped.

I introduced PCD tip inserts for finishing operation these insert produced quality parts for up to 6 months without any scrap.

These changes improved the throughput from 400 parts / shift to 700 quality parts / shift.

Next operation in this cell was drilling 10 holes (.904”), drilling 8(.501”) holes and taping 5/8 -11.

Operators were changing drills once a shift and breaking tap at least once a day.

Time spent to change drill and taps 3 hours / day and scraped at least 8 parts / day.

With the help of my tooling contacts changed the drills and taps that improved cycle time from 45 seconds to 35 seconds. The drills and taps lasted for 6 months.

Total saving was $165000.00 / year because of these changes.

I implement same tooling throughout the facility and same kind of saving were achived.

Implemented setup documents in the plant to help operators to identify tooling required for each job.

Setup sheet included the tool holders, inserts, shim seats, anvils, lock screws, drills taps collets, tool lengths and tool venders.

These documents help Conmet to receive TS16949 certification.

The coolant used in the plant had bad smell and it was harmful to operators.

Implemented new coolant in plant that is safe for operators and Oder free with annual savings of $125,000.00/ year.

Launched new product line called preset plus in iron and Aluminum material on 42 spindles in plant.

Traveled to Mexico, China and in USA to setup and launch products in different plants..

In these trips trained Engineers operators and quality personals and introduced new machining processes.

With these changes and improvements Conmet Monroe is the most productive and profitable plant in Conmet history.

Other activities in Comet included the following.

Purchasing and Justification

Process Improvement

Setup Reduction

Cost Reduction

Time Studies

ISO/TS 16949 Internal Auditor

Arvin Meritor

CNC Programming Tooling Engineer

Extensive hands-on experience in challenging manufacturing environments at Fortune 100 companies as well as the US military. Exclusively involved in all aspects of machining and the purchase of machines and suitable tools to insure superior part quality. Naturalized United States Citizen since 1987. Proven expertise in:

Machine Purchasing and Justification

Process Improvement

Setup Reduction

Cost Reduction

Time Studies

ISO/TS 16949 Internal Auditor

Professional Highlights

ArvinMeritor – York, SC

Tooling Engineer / CNC Programmer (1987-2007)

Developed and implemented innovative tool designs to improve processes, reduce cycle times, and eliminate scrap, rework and warranty costs for brake housing, cast shoes, spider, drum machining and multiple other products. Performed process studies and setup standards. Conducted ISO/TS 16949 internal audits and QC audits. Developed and maintained CNC setup and work instructions for QS/TS 16949 quality systems. Team member of continuous improvement PIE (process improvement events). Monitored and developed mistake proofing activities.

Designated as the company’s Outsource/Contract Vendor consultant. Traveled to outsourced vendor sites to set up processes and train programmers and tooling/fixing engineers to launch the initial product.

Developed a custom groove-milling tool for brake caliper grooves to improve a machining technique that was delivering inconsistent quality. Overcoming challenges with the U-shaped geometry and tight tolerances, the new tooling technique reduced the number of tools required, reduced cycle time from 25 to 8 minutes and eliminated scrap – which in turn reduced customer complaints and warranty costs. As a result of this improvement company was able to in-source all hydraulic disc brake products. Exhibited at IMTS (International Machine Tool Show) in Chicago, 2005 by PH Horn. Interviewed by Derek Korn and featured in Modern Machine Shop magazine, January 2006.

Improved the process for high-speed spider machining, a multi-station machining line consisting of 3 dial machines and a double spindle late. By implementing quick change tool design and improving tool management, reduced tool change time, enhanced tool life, and increased output from 500 to 900 parts/shift. As a result, ArvinMeritor York still produces the cheapest brake spider in the world - even cheaper than China, India and Brazil.

Designed and implemented a high-speed cobalt drill on high speed dial machine to produce four piston brake calipers. Drill cost went from $750 to $50 by replacing a carbide drill with a peck drilling process, with annual savings over $90,000.

When company acquired hydraulic disc brake business from Goodyear, implemented changes to eliminate manual machines and consolidate operations from 13 to six machines. Reduced manpower from 15 to 9 operators for all three shifts by reducing setups from 3 to one. As a result, this business became profitable. Received President’s Achievement Award, given to the top performer in the company, 1995.

Designed and implemented a multi-step drill tool for disc brake inlet machining. This tool eliminated customer complaints and reduced warranty costs due to leaking brakes – and was implemented throughout the company worldwide, 2002.

Developed an inserted broach for high volume fabrication shoe production to replace a high-speed steal broach, which will save $750,000 in 2007.

CNC Operator (1984-1987)

Quality Inspector (1981-1984)

Muhammad Afzal Cheema, page two

Education

B.SC (Pre-Medical Major) Dyal Singh College – Lahore, Pakistan

Professional Engineering Certifications

Machine Tool Operator - York Technical College, Rock Hill, SC, 1981

Geometric Dimensioning & Tolerance – ASME Y14.5M,1994

Toyota Fanuc CNC Programming, 1998

Mazak Mazatrol Programming, 1997

CADCAM, 2003

Bryant Grinder Programming, 2001

Training for specific machine installations for:

Haas, Fadal, G&L, Cincinnati Milicron, Allen Bradley and Siemens

Contact this candidate