Engineer Manufacturing

Thomas Faye

Sandy Hook, CT *****

*****.****@*****.*** 203-***-**** www.linkedin.com/in/thomasfaye

Lean Manufacturing Engineer with Project Management Skills

Continuous improvement manufacturing engineer that utilizes problem solving, Six Sigma methodologies in program management matrix environment.

Utilize strong leadership and effective interpersonal skills to support the business unit goal of achieving operational excellence. Cross-functional collaborative teamwork experience, working toward common goal of achieving set program milestones. Ensure timely, informative and effective supplier and customer correspondence.

Core competencies include:

Project Management Cost Estimation Change Management

Effective Communication Risk Analysis and Evaluation Decision Analysis

Resource Optimization Strategic and Operations Planning

Professional Experience

UNITED TECHNOLOGIES AEROSPACE SYSTEMS (UTAS), Danbury, CT 2007 – 2015

Manufacturing Engineer

Developed and manufactured aerospace electro-mechanical assemblies and electrical systems in accordance with customer mission performance, program milestones, and NASA-STD 8739. Provided hands-on technical support to cable, harness, printed circuit assembly and test departments. Methodized engineering drawings and wiring diagrams. Designed harness boards and procured assembly tooling as required.

Reduced assembly time 30% by developing and writing manufacturing operation sheets and production routings, utilizing standard operating procedures and photographic documentation.

Reached annual savings of $27K by standardizing processes which led to increased product quality and reduction in error potential.

Accelerated new product line 25% by creating parts and developing System Applications Products (SAP) product structure / bill of material (BoM) in expeditious manner.

Lowered UTAS lead times 23% by implementing competitive excellence, Achieving Competitive Excellence (ACE), an operating system with results focused on perfect quality, on-time delivery, and best-in-class financial returns.

Reduced tool locating time from average of 1 hour to seconds and attained ACE Associate Level by fabricating 5S tool shadow boards and introducing Systems Integration Lab to lean tools Standardized Work and Total Productive Maintenance (TPM).

Achieved several heater and string assembly program milestones valued at $3K each by designing, fabricating, and procuring necessary assembly tooling that performed processes in efficient, accurate, and repeatable quality manner.

Enabled UTAS to resume product shipments with revenue in excess of $3M by assisting in development of preheat and hot air soldering of thermally sensitive components in addition to creating process, generating work instructions, and obtaining capital appropriation approval.

Exercised mission statement… “You have to be willing to venture where nobody else is willing to go as well as provide a service that everyone needs” by offering real-time technical support while being stationed on shop floor for almost 2 years.

Thomas Faye *****.****@*****.*** Page Two

EATON AEROSPACE GROUP, Bethel, CT 1997 – 2007

Manufacturing Engineer

Provided Manufacturing Engineering support functions to Manufacturing, Engineering, Purchasing, Quality Assurance, Contracts as well as supplier liaison. Managed multiple projects in fast-paced electro-mechanical assembly and test environment. Ensured manufacturability then developed production plans, processes and procedures in accordance with new engineering product designs.

Attained highest Eaton Business Excellence Assessment score in Eaton Aerospace by spearheading Bethel's Lean Task Force continuous improvement activities.

Streamlined cycle time to 33% reduction by developing total process lean continuous flow cell of high volume assemblies for Boeing; optimized new process layout by balancing, resulting in an increase in productivity and cost savings while enhancing operational control.

Maintained subcontract and labor cost variances below 10%, meeting financial commitments by monitoring, changing, and controlling process cost variances during Mfg / Pro implementation, a standard cost operating system.

Performed Lean Tool Awareness and detailed Eaton Lean System Tool training plant-wide. Certified trainer for Value Stream Mapping, 5S, Standardized Work, Continuous Flow Manufacturing, Set-Up Reduction, Pull System, and Poke-Yoke.

Improved metrics rolled throughput yield (RTY) from 72% to 95%, cost of poor quality (COPQ) from 27K to 0.5K, Sigma from 2.1 to 4, defective parts per million (DPPM) from 275,256 to 50,000 and on-time delivery (OTD) from 85% to 95% by utilizing Six Sigma techniques.

Conducted root cause investigations, performed producibility analysis, implemented corrective / preventative actions and introduced process improvements as required.

Achieved $26K+ direct labor savings and $12K+ inventory savings, totaling $48K+ of savings by implementing lean tools Standardized Work, Pull System, and 1-piece Continuous Flow Manufacturing to 2nd new total process layout where high volume assemblies were manufactured for Boeing.

Accumulated annual cost savings greater than $26K+ by improving Honeywell Aerospace micro switch deadbreaks yield, eliminating scrap micro switches, and introduced process changes that significantly improved on-time delivery.

Reduced current change-over process from 2.5 hours to 45 minutes by implementing lean setup reduction steps.

Drove excellence, achievements, and savings by creating environment that promoted open communication and mutual benefit to company, suppliers, customers and encouraging supplier-initiated cost reduction and improvement suggestions.

Additional Experience

PERKIN-ELMER CORPORATION, Norwalk / Wilton / Ridgefield, CT

Manufacturing Engineer

Thomas Faye *****.****@*****.*** Page Three

Technical Skills

Problem Solving Skills:

Ishikawa / Fishbone Diagram, 5 Whys, FMEA, PFMEA

IPC Certified Skills:

IPC-7711 / IPC-7721, J-STD-001

Continuous Improvement:

Processes, Systems, People

Quality Management Systems:

ISO 9000, ISO 9001, ISO 14001, ISO/TS 16949

Databases:

Access, Java, Windows, Oracle

Software:

Microsoft Office 2000, Microsoft Office XP, Internet Explorer, MS Excel, MS Word, MS Project, Outlook, Adobe Photoshop, Outlook, PowerPoint, Publisher, AutoCAD, Pro Engineer, Visio

Tools:

Surface Mount Technology

Other:

Design for Manufacturing (DFM)

Education

BS, Technical / Program Management, DeVry University, Naperville, IL, summa cum laude

AS, Electro-Mechanical Engineering, Norwalk State Technical College, Norwalk, CT

Certifications

Six Sigma Green Belt Certification

ACE Certification Program

Lean Manufacturing

5S, Value Stream Mapping, Error-Proofing

Standardized Work, Continuous Flow Manufacturing, Pull System

Total Productive Maintenance (TPM), Setup Reduction

IPC Certified Specialist and Trainer

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