Injection Molding Engineer

Robert P. Jones

**** ********** ***** ******* ******, GA 30542-5362

678-***-**** Email: **********@*****.***

An engineering professional with extensive plastics background specializing in productivity and OEE improvement, identification and elimination of waste, visual documentation of processes and a history of success in reducing operating costs using Lean Manufacturing techniques coupled with exceptional trouble shooting and problem solving skills.

EXPERIENCE

HUMAN TECHNOLOGIES, INC. – Anderson, SC

Contract Position at PLASTIC OMNIUM AUTO EXTERIORS– January 2013 – April 2014

Assembly Engineer

Installation and validation of robotic plastic welding and assembly equipment for Tier One automotive supplier with better than 99% uptime one full year after 2013 launch.

Integration of additional tooling during plant shutdowns for new product launches scheduled for July 2014, December 2014 and April 2015.

Development of operator and maintenance work instructions for all launches, including training of personnel.

DECOSTAR INDUSTRIES, INC. – Carrollton, GA – April 2011 – July 2012

Continuous Improvement Engineer

Developed capacity database for all production operations to provide the ability to analyze the impact of part volume increases and quoting.

Re-engineered paint line un-load operation to reduce walking and improve overall efficiency by 7%.

Created new design for part conveyor to improve ergonomics by elimination of bending at waist caused by traditional belt.

SILGAN PLASTICS, LLC – Monroe, GA – April 2010 – April 2011

Production / Quality Manager

Implement improvements to reduce waste 10% for unbalanced process by establishing “mini runs” for plastic bottles due to downstream equipment constraints.

Implemented and maintained an Excel based productivity reporting system using Overall Equipment Effectiveness (OEE).

KEY PLASTICS, LLC - Grand Rapids, MI – June 1995 – January 2009

Continuous Improvement Manager

Implement improvements to reduce waste by 1.5% by DOE testing of injection molding processes.

Determined modifications to existing equipment and designed automation for insert molding and welding of plastic parts. Built test fixtures in house to reduce external expenditures.

Responsible for preparation of quotations for bidding on new business and modifications to existing business.

Designed, implemented and maintained an Excel based system to monitor and analyze recurring cost for all product lines.

Performed line balancing activities and studies to identify bottleneck operations using Lean-Manufacturing principles. Reduced number of operators required from 3 to 2 and from 2 to 1 for assembly operations.

Engineering Manager

Managed a staff of three engineers direct and 15 technicians indirect supporting a production operation with 40 injection molding machines and related assembly equipment.

Developed manufacturing processes and led troubleshooting, maintenance and repair of primary and secondary tooling for Tier One / Two automotive. Reduced scrap for problem job from 10% to less than 2%.

Lead Program Management and APQP activity and was responsible for new product launch activities at the division level.

KEY PLASTICS, LLC - Grand Rapids, MI – June 1995 – January 2009 (Continued)

Manufacturing Engineer

Managed APQP program activity including development of injection molding and assembly processes for new product launch at the division level.

Built prototypes and developed production processes for existing and transfer programs.

Determined opportunities for tooling and process improvements for existing injection molding operations.

Prepared all operator instructions for manufacturing from 1996 through 2009 and trained personnel for customer run at rate demonstration.

LACK’S ENTERPRISES - Grand Rapids, MI – February 1995 – June 1995

Shift Superintendent

WAMAR PRODUCTS - Grand Rapids, MI – February 1994 – February 1995

Shift Manager

ART OPTICAL, INC. - Grand Rapids, MI – March 1993 – January 1994

Process Engineer

CIBA VISION CORP. – Norcross, GA – January 1981 – August 1992

Operations Manager

Process Development Engineer

SIGNIFICANT ACCOMPLISHMENTS

Reduced freight cost for export product $45,000 per year by modification of pack to increase density.

Planned and accomplished transfer, process development and revalidation of more than 20 programs due to plant move and relocation of 20 injection molding machines and associated assembly equipment.

Developed document control systems for QS-9000, TS-16949 and GMP compliance.

Implemented Pre-Control documentation to replace SPC as primary control for manufacturing operation.

Incorporated work cell layout, photos and graphics into operator and pack instructions for manufacturing to improve comprehension and overcome language issues.

Developed Excel based database for calculation and tracking of recurring manufacturing cost.

Improved MRP Bills of Materials to include all subassemblies and improve reporting for cost calculation.

Created Excel based Capacity Database linking Paint, Injection Molding and Reaction Injection Molding operations to customer release data.

Reduced scrap for problem injection molding job from 10% to less than 2% using custom built vacuum system to remove air from mold during injection.

EDUCATION

Attended Georgia Institute of Technology - Atlanta, GA - 1977 - 1980 Major: Chemistry - No Degree

Currently attending Ashford University Online working toward continuing education with current 3.98 GPA. Inducted to Alpha Sigma Lambda National Honors Society for academic excellence.

Six Sigma Black Belt

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