Mechanical Engineer Manager

Joseph C. Fusaro Jr.

Mechanical Engineer and LEAN Practitioner/Educator

516-***-**** *************@*****.***

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EDUCATION Virginia Polytechnic Institute and State University Blacksburg, VA B.S., Mechanical Engineering in May 2001, Overall GPA: 3.41/4.00 (Cum Laude) COMPUTER Advanced MS Excel User AutoCAD Autodesk Inventor SKILLS Microsoft Word Microsoft Powerpoint Microsoft Visio Microsoft Outlook Pentagon MRP/ERP Familiar with MS Access TRAINING See Addendum

HONORS * Certified AS9100 Internal Auditor

* LEAN Bronze Certification from SME

* Complete CAD Design & Hands on Fabrication of every aspect of a complete Pilot House Fishing Vessel for self

* Achieved & Maintain a U.S. Coast Guard OUPV Charter Captain’s License with Radar & Towing Endorsements

* Received three (3) Pratt & Whitney Recognition Awards for contributions on Fighter Jet programs:

F 22/F119 and F100 229

* Volunteer Treasurer of the Cold Spring Harbor Seafarers Marina & Boat Club (non profit)

* Appointed company Chair of LIFT’s Lean Implementation & Training regime for 2009 WORK EXPERIENCE

2009 to Present Long Island Forum for Technology (LIFT) – Bethpage, NY Mechanical Engineer & Project Manager specializing in Lean Manufacturing Education & Implementation LIFT is a non profit organization that gets State and Federal funding to train manufacturing companies to become more efficient, therefore keeping business not only in the United States, but on Long Island.

Training and Education in Lean Manufacturing Principles

Implementation of Lean Tools and Techniques where training employees is not viable

Experience in many manufacturing companies across various industries

- Metalworking, Pharmaceutical Distribution, Job Shops, Assembly Work, Stone & Granite, Food Production, Precision Machining, Cosmetics, Military, Commercial, Electronics, etc.

The Scope of Projects last between 2 days and a full year

Company Wide Lean Transformation Programs or Point Applications of Lean Tools

Currently Train and or facilitate companies and employees in the following areas:

- Value Stream Mapping, Single Minute Exchange of Dies, Cellular/Flow Design, Kanban Systems, LEAN 101 Classes & Simulation, 5S, Root Cause Analysis, Poka Yoke, Toyota Principles, Innovation Engineering, familiar with Toyota Kata

Able to Perform

- Lean Kaizen Events that may touch all areas above

- Plant Layout for Manufacturing

- Lean Layouts using SLP (Systematic Layout Planning, Relationship Charting, Material Flow Analysis, Various Evaluation Techniques)

- Stock Room & Warehouse Layouts and Work Flow, Slotting, ABC123 Priority Movers

- Distribution Center Layouts

- Space Analysis – Stock Rooms, Manufacturing Floors, Entire Factories or Distribution Depots

Certified by IPC Soldering Programs to Train

- IPC-A-610 – Commercial Soldering

- J-STD-001 - Military Soldering and associated Space Travel Addendum Joseph C. Fusaro Jr.

Mechanical Engineer and LEAN Practitioner/Educator 516-***-**** *************@*****.***

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2001 to 2009 Davis Aircraft Products Bohemia, NY

Department Administrator (2004 – 2009) & Mechanical Engineer (2001 2004) Davis Aircraft is a Government Contractor of Cargo Tie Downs, Seatbelts, Helicopter Blade Folds Systems, etc.

*Administration Duties

Project Management – manpower scheduling & recommendations, timelines, light cost analysis, etc.

Administration of Engineering Server, Vault, File Store Systems

Standardized file naming and file structure – got entire company access to digital technical files

Methodized design process & blueprint checking

Lead and Engineering Representative the Defective Material Review Board

Design, Draft, and Approve all flowcharts company-wide – AS9100 continuous improvement

Perform regular AS9100 Internal Audits – make Recommendations, Observations & Findings

AS9100 Champion – Interface between AS9100 Training Institute and the company

Set departmental priorities – 6 Engineers & 1 Draftsman

*Engineering Duties

3-D modeling and design on entire company product line

Work under government contracts, to Military Specifications, and to Commercial Standards

Work closely with Quality Assurance to ensure continued quality of products

Chief Designer and Project Leader for Boeing Experimental Projects

8000lbf retracting synthetic cable device & 2500lbf indexing webbing retractor

Fully designed a recessed 10,000 lb floor plate for Draper Company

Complete design, testing, and prototyping of 10,000 lb adapter plate - Boeing retrofit

Blueprint approval, design checking, and stress calculations performed

Instrumental in redesigning components of Chain Gear (Military Cargo Tie-Down) 2001 to 2004 Davis Water Systems Bohemia, NY (Second Job) Plant Manager & Head Engineer – Water Filtration Manufacturer Start Up Company

Manager of up to 9 assembly floor workers and mechanics, supervised entire organization

Responsible for plant design, manpower and equipment requirements upon start-up of company

Cost analysis performed on comparable filtration, plumbing, electrical, and housing components

Testing of water filtration systems for efficacy of ozone and system robustness

Decisive input on purchases of manufacturing equipment based on payback period calculations

Logistics of assembly – cut assembly time in half from 1st set of units to 3rd set of units produced

Technical point of contact and customer support to both prospective clients and existing customers

Created a detailed 55 page instruction manual for the water filter

Provided critical input to owner’s decisions in staffing and layoffs 2002 to 2005 Insight Technologies Bohemia, NY (Second Job) Bookkeeper and Engineering Support Oil Burner Efficiency Research Group

Responsible for Invoicing, writing checks, contract review, and monthly reports

Converted entire ‘paper’ business into QuickBooks ‘electronic’ business in 2003

Provide engineering and manufacturing support to contractors during the design and prototyping phases of a handheld smoke detector and other research projects

In charge of Contract fulfillment and timeline execution

Review and provide input on technical documentation that is ultimately directed towards organizations such as DoE (Department of Energy), NYSERDA (New York State Energy Research and Development Authority), and NORA (National Oilheat Research Alliance) Joseph C. Fusaro Jr.

Mechanical Engineer and LEAN Practitioner/Educator 516-***-**** *************@*****.***

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1998 to 2000 Pratt & Whitney West Palm Beach, FL and East Hartford/Middletown, CT Rotational Program F100 229 & F119 F22 Fighter Jet Program – Electro Mechanical Systems and Components

Organized and obtained parts required for build up of a full engine lubrication system rig

Worked closely with machine shop on modification of parts

Reasoned acceptable instrumentation routing throughout rig

Organized timeline and supervised mechanics build-up of engine/rig

Designed/modified rig parts to accommodate testing requirements (axial loading clamshell)

Composed extensive daily progress reports on all active projects

Observed/reviewed test data and analyzed for problems and abnormalities in performance

Performed data reduction for 400 hours of variable speed/temperature and load testing

Analyzed ball and roller bearing life expectancy and lubrication system performance

Examined Flight Test Data using UniGraph

Analysis of carbon and labyrinth seals

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