Manager Project
Resume:
GREGG FIKES 210-***-****
https://www.linkedin.com/in/greggfikes *******@*****.***
Engineer / Manager
Accomplished, dynamic and results-oriented professional with a profound mechanical and manufacturing process aptitude. Distinctively combines machining, programming expertise and lean manufacturing principles to achieve a high level of success. Professional expertise includes expert knowledge and practiced experience in CNC machining, Machine shop management, 6 Sigma and team development. Designs and implements new systems and features to ensure the success of business initiatives. Notable professional achievements as a Production Manager, Project Manager and Manufacturing Engineer:
MANAGEMENT
oAuthored and implemented machining “Cookbook” integrated with ERP software complete with pictures and step-by-step instructions for set up and operation of repeated parts. System reduced machining error by 3%, improved set up time by 12% and cut training time in half.
oEffectively improved nonscheduled part staging and maintenance lead times by implementing Direct Accountability Matrix white boards throughout plant.
oUtilized creative visual management tools in conjunction with time bound productivity goals to boost key manufacturing metrics. All KPI’s continually improved by at least 1% per month by direct reporting departments.
oDeveloped a custom Visual Basic scheduling program designed to reduce wait time and increase throughput by strategically arranging work order operations by cycle time, set up time and machine capability. Productivity was greatly increased by the programs work-leveling algorithm.
oEffectively reduced shift turnover rates and greatly increased communication by the implementation of a server based shift report shared by departmental supervisors. Report covered Safety, Maintenance, Inspection, Quality and Production status at the end of every turn.
LEAN MANUFACTURING / SIX SIGMA
oChampioned team in the design of a production cell for the manufacture of heat exchangers for the HVAC industry utilizing a DFSS approach. The production cell reduced labor by 10%, reduced lead-time by 12.5% over previous batch processing methods.
oDesigned from inception a machining cell for the manufacture of fracking blocks to the oil and Gas industry. Through sound engineering practices and lean principles: the production cell reduced labor by 14%, reduced lead-time by 3% and increased throughput by 18%.
oDesigned and implemented an effective and efficient autonomous maintenance system to hold operators accountable and instill ownership at their work center. Coupled with a preemptive maintenance system, down times were reduced by 6% and replacement part lead times were reduced by 84%.
oImplemented a modified Kanban system that reduced paperwork errors by 13%. System incorporated an extra stage “Ready for Review” at every WIP process completed for supervisor approval. Circumvented searching for responsible operator at the end of production by introducing checks at each operation completed.
ANALYTICAL / PROBLEM SOLVING
oDeveloped adaptive machining processes using custom CNC macros and touch probe technology that reduced operator intervention by 6% and machining error by 14%.
oUsing “Chip Thinning Theory” designed an extended high feed Double Button cutter for machining flange relief profiles. Cutter eliminated the need for a second opposite hand cutting tool and increased the chip removal rate by over 25%.
oWrote a C ++ GUI based part estimation program that calculated material and production times to provide an accurate tool to use for machining estimations. Program improved Sales response times and saved an estimated 8% in sales force labor.
oDesigned and implemented a totally automatic machining coolant recovery and cleaning system for an environment of 30 CNC machines. System reduced coolant replenishment time by using automatic cycling and saved 50% in coolant costs by mixing new and recycled coolant.
MACHINING
oDesigned and programmed custom Tool Life Management macro that greatly improved versatility and usage over standard FANUC TLM software. The macro increased productivity by 4% by decreasing operator intervention at tool change.
oWrote a custom M code to delete “X” axis offsets during “C” axis milling in order to detour operator input error during set up. The macro satisfied a human error corrective action requirement difficult to implement.
oInvented a face milling operation that replaced slow single point facing with high feed helical milling to remove large amounts of material from sub sea oil field rings. Process removed 28 lbs/hour of material as opposed to 17 lbs/hour with a single point-facing tool.
oDeveloped a laser verified probe based measuring system for parts exceeding 200 inches in diameter to an accuracy of +/- .001. System saved 12% on inspection times and 5% on material handling due to inspection at the machine and part did not need to be transported to QC department.
PROFESSIONAL EXPERIENCE
LONESTAR SOLUTIONS – San Antonio, Texas – Production Manager 2014 – Sept. 2015
Manufacturer of Military Weapons components
Accountable for all manufacturing personnel in the facility including machine shop, weld shop, fabrication and assembly areas. Served as master scheduler and capability planner utilizing standard work and level production to achieve a balanced workflow. Responsible for continual improvement throughout plant connected to part process flow, router activity, employee training and workforce morale.
Effectively manage machine shop, fabrication and assembly departments to meet production schedule.
Establish productivity goals and ensure targets are achieved by actively monitoring employee productivity.
Calculate and report labor, machine efficiencies and goal oriented KPI’s for production lines.
Identified opportunities for reduced operational expenses and implemented solutions.
Establish new operating procedures used to implement time and cost reduction measures.
Provide expert insight relating to operational processes to take advantage of new technological methods.
Launched unique visual management tools to effectively boost employee engagement and productivity.
Ensure smooth and effective router and part operational flow utilizing lean manufacturing processes.
Championed process improvement objectives encompassing manufacturing, documentation procedures and quality.
ELLWOOD ROSE - Houston, Texas – Shop Supervisor / Project Manager 2013 – 2014
Large part machining facility for subsea oilfield
Managed skilled workforce across several plants. Required to continually reduce material handling and increase throughput of large machined parts by effective planning and accurate hourly job boards. Leader for entire plants 5S initiatives and head process improvement changes as project manager.
Manage and schedule 5 production departments and 40 manufacturing employees.
Maintained departmental budgets for labor costs and machine perishables.
Implement and sustain 6 sigma and lean methods throughout plant encompassing 6S to include safety, Kaizen events,
point of use inventory and daily E3 meetings for employees.
Analyze, estimate, and communicate production costs for large CNC machining centers including lathes and mills.
Update and maintain the integrity of job boards and visual management tools daily.
Ensure a smooth transition between shifts through effective communication and accurate information.
Directed cross-functional teams towards continual improvement projects utilizing lean methodologies.
Lead drill down root cause analysis process from shop floor cause to corrective action implementation
API KETEMA – Heat exchanger division – Dallas, Texas – Manufacturing Engineer 2002 – 2013
Shell and tube heat exchanger and package refrigeration equipment manufacturer
Own manufacturing processes regarding optimized part process flow, fixture design, efficient machine tool programming and accurate manufacturing cost estimations. Required to analyze production mechanisms and reduce waste utilizing lean strategies.
Provided solutions, troubleshooting and tooling for the manufacturing processes of heat exchangers.
Identify prospective bottlenecks and strategically improve flow through sound engineering practices.
Design customized tooling and fixtures used to perform specialized tasks, including Lathes, VTL’s and Mills.
Prepared product and training manuals for customers and employees.
Prepare and deliver proposals for new products and present technical advantages, availability and installation for review.
Provide technical support to staff members regarding product process, function and ASME code requirements.
Provide tooling cost and estimation times of multi-million dollar projects.
ABBOTT LABORATORIES – Research and Development – Irving, Texas – Software Engineer II 2000 – 2002 Manufacturer of medical diagnostic equipment
Research and developed software testing techniques for the operating system on medical diagnostic and testing equipment.
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Provided object oriented software designs in C++ for the development of diagnostic equipment.
Created and deployed software testing code with the use of Silktest for nightly builds.
Developed technical solutions that improved scalability, performance and profit.
Assisted in the design of GUI based user interface.
API KETEMA – Dallas, Texas – Cost Estimation Engineer 1998 – 2000
Shell and tube heat exchanger and package refrigeration equipment manufacturer
Responsible for estimating product cost then subsequently validating manufacturing hours, material costs and consumables at job completion. Continually strive for improved manufacturing processes and cost effective incentives. Required to maintain material costing database for improved accuracy in estimating.
Provided customer solutions, troubleshooting and design order implementation.
Identify prospective cost saving measures and strategically implement through sound engineering practices.
Prepared product and training manuals for customers and Sales personnel.
Prepare and deliver technical presentations for prospective clients and present advantages, availability, installation and cost.
Provide technical and non-technical support and services to clients and staff members regarding product process.
Established material costing and labor estimation of multi-million dollar projects.
API KETEMA – Dallas, Texas – Night Shift Supervisor 1995 – 1998
Shell and tube heat exchanger and package refrigeration equipment manufacturer
Responsible for entire company grounds and all night shift employees. Ensure a smooth transition between shifts and maintain productivity standards throughout the night turn.
Production Scheduling for up to 35 employees including welders, assemblers and machinist.
Ensure all safety standards were followed to OSHA requirements.
Communicate with Engineering department about print discrepancies and necessary manufacturing changes.
Order tooling, machine perishables and communicate with outside tooling vendors to insure the
Latest and most efficient tooling was being utilized.
Effectively train machinist and insure that the best machining practices are always being used.
Ensure the physical plant is locked and secure at end of shift.
API KETEMA – Dallas, Texas – Maintenance Supervisor 1992 – 1995
Shell and tube heat exchanger and package refrigeration equipment manufacturer
Maintain all building and company grounds to corporate standards utilizing indirect staff and outside services. Uphold facility to all OSHA safety requirements and city building codes. Manage and effectively dispose of all hazardous waste within the facility.
Continual upkeep of machines that were needed to facilitate continuous production.
Preventative and preemptive maintenance scheduling for 5 maintenance mechanics.
Recommend and implement changes to improve operational efficiency and profitability.
Observe and evaluate the effectiveness of present equipment and collect data for the justification of new machines.
Acquired quotes and selected contractors for construction projects.
Work closely with production supervisors to maintain efficient and safe working environments.
Ability to accurately interpret complex drawings and communicate with staff regarding necessary changes or capital for upkeep.
API KETEMA – Dallas, Texas – Lead Machinist 1988 – 1992
Shell and tube heat exchanger and package refrigeration equipment manufacturer
Responsible for the set up of metal cutting tools and training machinist in proper settings and good machining practices required during machine tool operations. Machine heat exchanger components to print specifications.
Set up and run Manual and CNC machine tools as required.
Accurately interpret complex mechanical drawings.
Complete all paperwork and first articles as required.
Repeatedly machined parts measuring over 100 inches and consistently held tolerances to .001.
Upkeep and daily maintenance on machines as required.
Heavy lifting of up to 50 tons with cranes and forklifts as necessary.
SKILLS
TECHNICAL: FANUC, Fadal CNC, Mazak, Bullard, Homma VTL, Toshiba CNC, TOS, Yougi, Okuma, G&L, Amada, Renishaw probes, Custom Macro Programming, G code programming, C/C++ programming
PROFESSIONAL: MS Office, Excel VBA, Global Shop, Syteline, WO Scan, Class A journeyman machinist, Continual Improvement, Lean manufacturing, Training and Team Building
EDUCATION
Bachelor of Science, Computer Science and Engineering, 2000 - UNIVERSITY OF TEXAS AT ARLINGTON.
Green Belt Six Sigma Certification, 2015 - UNIVERSITY OF TEXAS AT AUSTIN.
REFERENCES
Mr. Paul Sollberger
Department Manager
TMK IPSCO
Mr. Mike Furst
Vice President
Lonestar Solutions
Mr. Richard Wilson
Machining Engineer
Lonestar Solutions
Mr. Bill Layton
Quality Manager
Lonestar Solutions
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