Process Improvement Engineer

Hands-On, Industrial Engineering position responsible for identifying, developing and implementing improvement projects that utilizes my engineering experiences to DRIVE changes that ELIMINATES WASTE, impacting the bottom-line.

Summary of Qualifications

Bachelor of Science in Mechanical Engineering – Clemson, South Carolina

Data Collection / Analysis to evaluate statistical data to determine and maintain quality and reliability of products.

Prepare charts, and diagrams that illustrated routing, workflow, floor layouts, material handling, or machine utilization.

Quality experience with SPC Process Control programs dealing with controls & spec limits, Xbar R Charts used to determine out of control conditions and processing quality defects using 8D’s - 5Why’s

Conducted time study and speed evaluations to establish standard production rate or improve efficiency.

Revised operation methods, material handling, and equipment layout that increasing production or improve standards.

Perform time / motion studies on operations that established standard production rates or improving efficiency.

Managed Assemble process, where components were manufactured in a fast paced, high volume, AUTOMOTIVE, and customer focused environment with stringent quality environment using QS 9000 / TS-16949

Managed improvement teams that utilized Lean Sigma techniques to reducing cycle times and labor costs

Generated and prepared APQP, PPAP, FMEA’s, Process Flows, and Control Plans for new and existing product lines

Facilitated projects by documenting activities, monitoring action items, and communicating progress

15+ years experience using AUTOCAD 2000 CAD software

Manage design projects from concept through production

Over 15 years’ manufacturing experience with process improvement methods and techniques

Handle daily issues by work closely with production and floor associates

Self motivated with excellent written and verbal communication skills

Proven ability to communicate effectively at all levels of management

Computer proficiencies - MS Word, Excel, Visio, Access, Project, MINITAB, Auto-CAD, & SQL Query Analyzer

Achievements

Conducted Two (2) On-Site Lean Six Sigma Projects at Customer’s Plant, identifying variation issues, and designed product enhancements that resulted in 8% net sales increase of $2.4 million.

Two (2) Gates Award Finalist for applying teamwork and innovative solutions to better serve customers

Passed ASI Food Safety Audit with a 96.4% rating

Innovation Award Winner – Pick-List Elimination, revolutionizing shop floor operations.

oAutomated Induction Process; Eliminated Manual Tote Handling; Implemented new Pick-to-Light (PTL) system that tracked assistant accountability; Moved labeling printing to packing operations

oProject Performance results – 25% Direct Labor & 22% Picking Improvement

Lead 15 plus Kaizen events with leads and floor associates improving their area of operation

Developed Daily Production Scheduling Process that enabled managers to plan and coordinate daily operations

Introduced daily shop floor GEMBA walks that utilizes graphic boards to post current results and issues

$5.2 million Total Project Savings to-date with 30 plus Lean Sigma Project Completions

Achieve ISO audit certification at Black & Decker

Performed Design of Experiments (DOE) on Relief Valve that reduced customer’s scrap rate from 3% to 0.4%

Integrated Vision Inspection System onto assembly machine that inspected for defected annual savings $80K

Integrated Leak Testing Instruments and Fixtures into core assembly machines with annual savings of $120K

Professional Experience

Performance Fibers Inc. – Winnsboro, South Carolina Aug2014-July2015

Process Engineer

Managed and Lead KAIZEN Teams utilizing Lean Sigma techniques resulting in process improvement in areas of Safety, DPMO, Cycle Time, Inventory & Manpower improvements

Responsible for planning, developing and executing detailed Lean activities to support Process Improvement projects, working with production staff to develop scope with detailed action plans

Facilitating projects by documenting activities, monitoring action items, and communicating results and progress

Lead Safety and Housekeeping Audit Team, conducting weekly audits, publishing results with scores

Constar International Inc. – Charlotte, North Carolina Nov2011-May2014

Manufacturing Lean Engineer

Responsible for planning, developing and executing detailed Lean activities to support Process Improvement projects, working with production staff to develop scope with detailed action plans

Line Performance Improvements were seen by reducing scrap & unscheduled downtime resulting $210K savings

Eliminated Secondary Storage Warehouse by utilization space throughout the production floor- $187K savings

Stanley Black&Decker - Kwikset Inc. – Charlotte, NC Jan2005-Oct2011

Lean Sigma Engineer

Using Lean Sigma tools and techniques to drive process improvements, focusing upon key business drives that influence Customer Satisfaction, Waste-Elimination, Growth Cost Effectiveness and Product/System Quality

Managed and Lead KAIZEN Teams utilizing Lean Sigma techniques resulting in process improvement in areas of Safety, DPMO, Cycle Time, Inventory & Manpower improvements

Conducted Lean training that involved all levels of the work force – Shop Floor Associates to Plant Staff

Monitored project milestones, timelines and savings, reporting and presenting monthly updates

GDX Automotive Inc. – Salisbury, North Carolina June2003-Jan2005

Process Improvement Manager

Managed Improvement Projects - leaded, identified, and redesigned concepts and practices that drove process optimization through analytical data driven solutions

Reduced rejection rate from 30% to 9% that increased production capacity and lowered overall Material and Labor cost.

Revised and created specifications, work instructions and procedures after changes were made and validated

Mentor six (6) Green Belts through certification to project completion goals

Schrader Bridgeport Inc. – Monroe, North Carolina Sept1997-Jun2003

Manufacturing Engineer – Production Support

Managed multiple Assemble process, where components were manufactured in a fast paced, high volume, AUTOMOTIVE, and customer focused environment with stringent quality environment using QS 9000 / TS-16949

Managed improvement teams that utilized Lean Sigma techniques to reducing cycle times and labor costs

Coordinated 5-Why’s for internal / external customers that corrected, eliminated or reduced process quality issues

Generated and prepared APQP, PPAP, FMEA’s, Process Flows, and Control Plans for new and existing product lines

Capital project management – Screw machine overhaul

MGM Brakes, Division of Indian Head Industries, Inc – Charlotte, North Carolina Oct1995-Sep1997

Project Engineer

Design brake actuators for Volvo, Freightliner and other trucking industries, coordinated projects from concept to production

Responsible for new product development, product engineering improvement for manufacturing support

Optimized stampings, castings and injection-molded parts resulting in a $1.5 million cost savings

Education

CLEMSON UNIVERSITY - Clemson, South Carolina

Mechanical Engineering, Bachelor of Science

TRI-COUNTY TECHNICAL COLLEGE, Pendleton, SC

Engineering Graphics Technology

Military Service

SOUTH CAROLINA ARMY NATIONAL GUARD – Anderson, South Carolina 1984–2006

Tactical Officer

Planned and coordinated training for soldiers to work as coherent force capable of performing combat missions.

oAwarded BEST BATTERY for outstanding performance

oReceived five (5) Army Achievement Medals for distinguished service and leadership

Lean Sigma Project Details

Provided upon request or see on LinkedIn

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