Engineering Engineer
Resume:
Yusheng Zhang, B.S.M.E.
actlg5@r.postjobfree.com
https://ca.linkedin.com/in/zhangyusheng
MANUFACTURING ENGINEER
Value Engineering Project Engineering Process Engineering Automation Engineering
Innovation, broadly experienced, forward-thinking with 22+ yrs integrated applied electromechanical engineering experience on fast-paced manufacturing environment.
Strong project management capability proven in multi-million dollar projects in Detail-orientated
Exporter Continuous improvements in mfg at automation equipment engineering strategies
Extensive knowledge on Six Sigma, Lean / Kaizen, SPC, DFMEA, 5S methodologies, with real-world application to maximize production line OEE
Extensive expertise in Baan, AutoCAD, Solidwork, ProEngineer, ANSYS, PSPICE, Minitab, Dreamweaver, SharePoint, Photoshop, Microsoft Office Suite, SAP, Agile, Autovue, Team center, APQP, Core Tools, C, C++, HTML, VBA, MATLAB, TLGIS, IREIS, CNC, GD&T
Strong background in IPC, UL, ULC, CSA, ISO, CCC standards AWARDS
Received a Living the Tyco Values Award – Teamwork Honoured with a Tyco Club Excel Award for Continuous Improvement to lean-out pro significantly and to greatly improve the efficiency in Shipping, thereby resulted in over $100,000.00 savings PROFESSIONAL EXPERIENCE
Tyco Security Products 1993 - 2015
Manufacturing Engineer / VAVE Engineering 2001 - 2015
Delivered 6+% cost reduction in 10+ consecutive years through various projects
Led Cross-Functional teams on production data analysis, corrective actions, and resulted 100% productivity and 98% FPY. Provided solutions for Production & Engineering Issues log
Improved auto-assembly line OEE from 55% to 83% by (1) installed auto-pins-support system and
(2) added AOI (automatic optical inspection). Reduced changeover downtime from 4.5hr to 3,75hr by modules setup combined with thermal processes
Failure Analysis on motion detector through DFMEA, Control Plan, SPC methodologies to improve FPY (first-pass yield) from 80% to 95% by selected reflow process, reduced repair labor $6K yrs
Standardized packaging operations by (1) reduced 50% variance shipping boxes by consolidation,
(2) designed, built 6 packaging lines, and (3) installed 3 Vacuum Lifting systems
Re-designed heat-sink geometry to obtain minimum clearance for auto-assembly process with annual $150K labor saving yr by Six-Sigma Green Belt project
Invented a auto de-paneling machine, with designed and built boardflow unit resulted HC by 3 full- time operators yrs and specified into the Design Guideline
Adapted a clamshell package technique with designed and built air-workbenches to eliminate 73% electrolytic capacitors shipping damage on control unit
DFA (design for assembly) on a 5-pin, 31-pins connector modification for auto assembly instead of manually resulted annual $83K saving and HC by 2 full-time operators
Eliminated 78% silkscreen defects on metal enclosure by (1) optimized chemical combination of paint and coating, (2) designed and built semi-auto pneumatic index flow rack Yusheng Zhang, B.S.M.E. P a g e 2
Managed annual $60M products contract with offshore mfg through doc biting, project plan, specified assemblies, PER’s (production evaluation run), and golden sample built. Validated AVL (approved vender list), FAI. Created Cosmetic Critical. Developed operator Skill Metrics
Key member on equipment selection, installation, maintenance, and life-cycle assessment, Fixture and Gauge designed. Maintained master lists of JIS, set-up instructions, and equipment performance indicator charts. Designed and built a gravity conveyor for vision system assembly
Responsible for sustaining engineering activities included part, module to enclosure assembly. Maintained PWI (production work instruction). Reviewed and approved ECR (engineering change request), TPD/R (temporary production deviation / requests), and issued rework instruction
Developed new techniques Potting, Conformal Coating, Bonding, Stamping, Curing, Foaming, Washing, and Foam pack with process setup, equipments installation and training
Installed 5 Automation Lines and practiced AutoCAD on plant layout and cell detail on TaKT time, process flow setup and achieved targeted output. Identified and specified the requirement for Production Tooling and assembly aids for new / existing products
Liaised APQP, R&D for annual 6 NPI launch, cost analysis, defined mfg process and set routings. Created and maintained BOM. Provided Design Reviews, Assembly Drawing and identified alternative manufacturing technique and process. Developed operator skill metrics Maintenance Team Leader 1996 - 2001
Led team to support entire plant relocation project on facility layout, production lines re-installation, calibration, PSSR
Established maintenance escalation procedures, lockout procedures
Defined illumination calibration procedure for Siemens component recognition camera
Designed / built a Interlock system and safety barricade on traditional equipment to achieve record of “no-lost-time” accident in 19+ consecutive yrs
Set up PM (preventive maintenance) schedule, procedures handbook for all equipment, Reduced 53% External Service calls and scheduled downtime, Created certification program for recruits Mechanical Technician 1993 - 1996
Programming AI and SMT machine pattern, established component database
PM on all production equipments and executed troubleshooting on electrical, hydraulic, mechanical and PLC control systems
SA Armstrong Ltd, Toronto 1992-1992
CNC lathes
Koch Heat Transfer Canada, Toronto 1991-1992
Tube bending, pump, valve assembler
Prior to 1990 worked in China as Certified Mechanical Engineer EDUCATION & PROFESSIONAL DEVELOPMENT
Mechanical Design and Graphics Certificate, AutoCAD, Ryerson University
Turbine Engines Certificate, Centennial College
Queens University
DMAIC Six-Sigma Green Belt from Tyco
Humantech’s Applied Ergonomics Process and Design at Tyco
Design Plant Layout Through Lean Manufacturing Certificate at Tyco
Project Management Professional training, Toastmaster at Tyco
AI and HSP Program, Maintenance, Universal. Splace Program, Maintenance, Siemens
Bachelor Degree in Mechanical Engineering, Shanghai University of Technology
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