Manager Project

LAWRENCE J. LUPINSKI

**** **** ***** ***** ****: 814-***-****

Erie, Pennsylvania 16510 Mobile: 814-***-****

actomk@r.postjobfree.com Office: 814-***-****

actomk@r.postjobfree.com FAX: 814-***-****

Highly organized, dedicated & achieving Management & Engineering Professional offering 30+ Years of Manufacturing Experience, with a winning record of performance in initiating and leading Improvements that have Streamlined Operations, Optimized Efficiency, and Increased Production. Intuitive Problem Solver & Skilled in Prioritizing Tasks, Delegating Responsibilities, and Motivating Team Members. Performance Driven to Transform Theories & Ideas into Reality & Profitable Enterprises. Tradition of Performance Excellence in Multiple Areas, Products, Processes, Operations, Roles, and Responsibilities including:

- Engineering (Process, Manufacturing, Risk, Quality, Design), Manufacturing & Materials Management;

- Twelve Years Diesel Engine & Transmission Design, Machining & Assembly Engineering Skills

- Equipment & Facilities Acquisition, Capital Budget Experience (using Business Case), P & L Responsibility;

- Start Up Engineering: Experience in Facilities, Equipment, New Models, Shifts & Cell Set Ups; DES (Simio);

- Manufacturing Technology, Product Development, Systems Management (CNC; SAP; Oracle; Team Center).

- Managed Metal Stamping, Welding & Brazing, Paint Shop, Automotive & Electronic Assembly Operations;

- Plating, Corrosion Prevention, Heat Treat Technology, Film Application; Plasma Therm; Semi-Conductors.

- Quality & Process Control (ISO, AS9100, TS-16949), Methods Improvement, Cost Reductions, PPAP’s, PFMEA;

- Planning, Integrated Logistics, and Supply Chain Management, MRPII/ERP, DDMRP, CRP;

- Project Management (>100 Projects including multiple million dollar+); PMP Certification; Oobeya process.

- Safety & Ergonomics, Waste Water Treatment, OSHA, EPA & Hazmat Compliance;

- Proponent of Team-Concept Management and Lean Manufacturing Disciplines (TPS, TQM, Kaizen, JIT,

- Product Systems Expertise: Cellular, Flexible, Value Stream, KanBan, 5-S, Poka Yoke, MOST – Mini & Maxi);

- Advocate/Practitioner of Self-Training/Certification (APICS Certified, Green & Black Belts in Six Sigma).

Certified in 8-D Problem Solving; A3 Problem Solving; Lean Manufacturing Guru); ROI Calculations & Validation.

- Excellent Verbal & Written Communications Skills, Including Presentation; Formal Training - German & Spanish.

PROFESSIONAL EXPERIENCE

General Electric Transportation Division, Erie & Grove City, Pennsylvania; Fort Worth, Texas; San Luis Potosi, Saltillo, Mexico.

Industry leader in manufacturing of diesel – electric locomotives, rail signaling & operations control centers, engines, mining

drive systems, drilling motors, stationary power & energy storage products.

SENIOR PROCESS & METHODS ENGINEER (07/2012 – Current)

Lead quality & manufacturing projects, and correct process issues in multitude of areas, including framing or chassis, new engines & related processes, corrosion (including oxidation) prevention, contamination control, welding (including pipe) & brazing issues, petroleum products problems, coating, thermal spraying, paint, masking, machining, and operations set ups. Leading role in Digital Factory Implementation & set up of new Fort Worth Locomotive & Mining Equipment operations. Established ISO clean rooms, new masking technology, coating operation areas, electrostatic powder coated paint systems, and design & development of a multiple station machining center. CNC expertise. Process PPAP documents on locomotive engines & related electrical motors.

LOCOMOTIVE DIESEL ENGINES: Leading role in resolving engineering issues (including improvement projects) of current & past engines; and in new generation of engines. Latter includes design & visual interpretation of Tier IV engine & components, using computer aided 3D design software, deciding on appropriate production materials, engaging in cost effectiveness analysis, solving reliability, safety & environmental impact issues of new design, developing & testing prototypes, research & develop machining & equipment related to engine production, planning production run, setting up assembly area, and monitoring cost & quality control.

Bell Helicopter (Division of Textron Corporation), Grand Prairie, Texas

ISO9000 certified manufacturer of helicopters and other vertical lift flight equipment for commercial and military applications. Plant Processes: Transmission & Engine Assembly; Gear Machining & Plating; Heat Treating.

CHIEF, MANUFACTURING AND PROCESS ENGINEERING (ENGINEERING MANAGER) (09/2008 – 07/2012)

Led engineering & technical team in assessing critical variables of a vertical lift transmissions’ & engines’ manufacturing process, including BCA; led engineering team which determined the most appropriate development tools, established a coherent process improvement plan and oversaw the execution and analysis of the manufacturing runs. Handled all

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engineering issues related to engines & transmissions, including new equipment & machinery, materials & process flow. Expert contact for core processes, CNC. Provided support in coating & heat treat operations, welding (including laser) & brazing, painting processes, and corrosion prevention issues. Assist, train, and evaluate technical team’s skills and ability to analyze processes for flow and process capability improvements. Managed all technical projects, implement process controls, automation systems, and data packages related to engines & transmissions, introduced and expanded use of 8D and A3 processes, and integrated value stream analysis into the technical team’s approach. Technical project manager over startup of new 50 million dollar plating and heat treat facility, and developed process alternatives for the facility space that was abandoned as a result. Worked with Quality on issues & handled PPAP’s on process problems. AS9100 certified.

International Truck & Engine (SST), Garland, Texas

ISO9000 certified manufacturer of rough service, heavy duty, and transfer trucks; diesel engine and truck assembly.

AREA MANAGER (02/2008 – 07/2008)

One of four area leaders reporting to plant manager. Responsible for directing engineering & manufacturing activities of one area of plant including chassis, engine assembly, trim & setup, engine installation, chassis/frame set up before and after paint, welding. Extensive CNC work. Directed line balancing, bottleneck investigations, and cost reduction efforts. Had three supervisors & engineering team directly reporting to me and indirect hourly crew of 150 employees. Responsible for all area goals (production levels, quality, safety, scrap, materials, budget, tooling, equipment, process control, continuous improvement, training, lean activities, six sigma, line balancing, engineering, employee motivation and discipline).

Cummins Filtration Systems, Cookeville, TN

TS-16949 certified manufacturer of air, fuel, and oil filters for automotive & truck engines, and other equipment.

OPERATIONS MANAGEMENT (05/2007 – 02/2008)

Led 2d shift manufacturing operations of 500+ employees in the manufacture of air, fuel and oil filters, including process mapping & line balancing, equipment & tooling acquisition, media production, metal forming, assembly, and paint operations. Responsible for all second shift team goals (production, quality, safety, equipment, materials, scrap, process control, budget, continuous improvement, lean activities, six sigma, value stream mapping, line balancing. Directed engineering activities, and initiated and led a multitude of projects.

Peterbilt Motors Company (Division of Paccar Corporation), Madison, TN

JD Power award winning manufacturer of transfer and heavy duty trucks; CAT & Cummins engine assembly & install.

AREA LEADER (06/2004 – 02/2007)

Direct manufacturing & engineering activities in assembling & installing CAT & Cummins engines, and other truck assembly activities. Oversaw & directed engine & transmission process & manufacturing issues, laser & arc welding, truck chassis, truck interiors (including flooring), process mapping & line balancing, machinery & equipment acquisitions & set up, cost & labor reduction, electronic testing, rework & scrap activities. Led start up efforts of new generation of truck engines, including process & cell set ups, production materials, equipment & tooling acquisitions & set up, and resolved engineering, quality, cost and safety issues. Led all 2d & 3d shift start up activities & manufacturing set up, including CNC, process, equipment & machinery, costs and quality responsibilities Responsible for accomplishing all team goals (production, quality, budget, safety, scrap, tooling, materials, quality, continuous improvement, safety (STOP), line balancing, training, etc.).

BMW Manufacturing Corporation, Greer, SC

Quality leader in design, manufacturing, and sales of luxury automotive vehicles; Greer facility annually produced

110,000 sports utility vehicles (X-5), and 45,000 Z-4 sports cars. Handled all incoming BMW vehicles’ set up & quality issues, and resolution.

SECTION LEADER (09/2000 – 09/2003)

Managed 4 different areas in assembly & install operations for the BMW X-5 SUV. Processes included chassis, gasoline & diesel engines, transmission assembly & install, laser welding, electrical harnesses, carpeting, padding & sound deadening install, brake modules, tail lights, steering wheels, air bags, brake & fuel lines, roof rails, running boards, doors, sunroofs, carpet panels, interior trim & other components (instruments), and many other operations. Handled engineering & process issues, budget, quality (including supplier-related), materials, rework, machinery maintenance, process control (including ISO 9000 issues), ergonomics, line & station balancing, safety. Quality initiative proponent & member of Continuous Improvement Activities Committee, conducted process audits throughout plant; manager over a number of different sized & budgeted projects. Led efforts for introduction of Six Sigma, JIT, Kaizen, and 5-S activities into production lines.

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Royston Corporation, Royston, Georgia

Metal stamping & finishing operation. Largest manufacturer of finished metal products for interiors and exteriors of service stations, supermarkets, convenience stores, and restaurants (cabinets, merchandisers, counters,

display units, signs, lights, facia). Operations included use of multi-hundred ton press brakes, benders, tube & laser cutters, welders, including robots; full powder based paint shop, packaging, delivery and installation.

PRODUCTION MANAGER (11/1996 – 9/2000)

Directed production, planning, product development, plant & machine maintenance, inventory control, materials acquisition, scheduling (MRP/ERP), quality (PFMEA, QS9000, AWS, ASME, NACE, Six Sigma), process performance (ISO 9000), methods improvements (lean manufacturing, TPS, Kaizen, value stream mapping, KanBan, JIT), cost tracking & reductions (using SPC & SAP), shipping & transportation, scheduling of onsite installation, OSHA & EPA compliance (Hazmat), ergonomics, safety, employee relations, training & motivation. Managed 7 direct reports, 14 indirect reports, and 300 hourly associates over two full shifts, and a third reduced shift.

- Production Improvements. Increased plant production efficiency from 75 to 95% within 2

years through good manufacturing practices, introduction of lean manufacturing techniques, ongoing

employee training, and selected capital expansion. Developed & maintained performance measurements for key cost elements to ensure annual performance improvements.

- Capital Expansion/Project Management. Managed three major improvement projects: one,

change from wet to powder based, electro-magnetic paint system (cost reduction of 60% within 3 years); two, change to new information/data/planning system (SAP) emphasizing MRP/ERP; three, construction of on campus warehouse for materials, WIP, and finished products storage (eliminated rental expenditures, related costs reduced by 35% within 3 years).

- Operations Management. Pioneered process streamlining, use of SOP’s, and emphasis on lean

manufacturing techniques. Reduced labor costs by 25% within 2 years, raw materials inventory by 30% within 3 years, WIP by 60% within 3 years, and virtually eliminated storage of finished products within 4 years (build to order only). Implemented KanBan inventory management.

- Technology Implementation. Championed active use of MRP/ERP software and SAP system

for manufacturing & administrative enterprises, integrating manufacturing into cross-departmental functions. Initiated computer-generated reporting for improved inventory control and customer service. Successfully pushed modernization of metal forming equipment, emphasizing use of electronics, hydraulics, & computer software for greater precision. Modernized Welding processes per AWS recommendations.

- Safety Management. Introduced STOP safety program and training for all associates, preaching

techniques developed at DuPont; advocated modernization & maintenance of equipment guards, lock down procedures, and use of PPE. OSHA recordables reduced by 50% within 3 years.

- Relationship Management. Maintained positive relations with employees, outside vendors & suppliers,

& suppliers, executive management, customers, and industry colleagues. No unionization attempts

during my tenure. Revitalized customer service by upgrading complaint responsiveness from a low of

20 days to a consistent response time of 3 – 5 days.

Motorola Corporation, Energy Products Division, Lawrenceville, GA, Boynton Beach, FL

Fortune 100 electronics components manufacturer. This operation produced semi-conductors, battery units for two way radios & cell phones, charging units for same, sensor (chemical, pressure) equipment, electronic mother boards for radios, phones and pagers utilizing electronic component placement robots/machinery, ovens, and manual assembly lines.

PRODUCTION & MATERIALS SUPERVISOR, PLANNER (5/1987 – 11/1996)

Supervised materials support, shipping, receiving, logistics, transportation, automated distribution aspects (including bar coding), pick & pack, raw materials, WIP, finished goods, all supply chain functions. Initial position was Production Supervisor managing 3 lines of associates (95 total) engaged in electronic assembly & rework; plasma therm; oversaw budget, quality, efficiency goals, production deadlines, process requirements (using SPC), employee relations & administration. On materials & planning side, performed MRP/ERP analysis using SAP & Oracle, controlled MPS,

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including forecasting & performance for battery unit production; monitored inventory levels to minimize lead times, ensure accuracy, and contribute to efficient, cost-effective Operations; managed slotting, purchasing, logistics, ISO9000 compliance, PFMEA techniques, quality control.

- Production Improvements. Increased line production efficiency 85 to 95% within 3 years.

Reduced costs by 50% within 2 years. Improved on-time delivery from 85 to 93% and lowered reject rate to less than 1% within 3 years. Streamlined area operations, intensified training efforts, and re-organized rework cells to achieve efficiency goals.

- Materials/Logistics Improvements. Managed inventory of over 250,000 parts, reduced costs (JIT)

by 70% within 18 months, achieved 98% inventory accuracy for 3 years.

- Established procedures for on-line receipts of inventory, to create live inventory transactions.

- Reduced lead times for components, sub-assemblies, and assemblies by 35% over 2 years.

- Reduced obsolete inventory & recaptured warehouse space; identified unused/old parts and reduced inventory from peak of $30M to $18M within 18 months.

- Initiated monthly reports to management detailing inventory volume and cycle time data.

- Directed product shipment through cross-functional collaboration with manufacturing, sales, import-export, and customer services departments; obtained consistent record of on-time delivery at lowest possible cost.

- Saved $250K+ in annual costs for freight carrier service by researching rate schedules, and assisting in negotiating first-ever, low-cost corporate contract with major carrier.

- Initiated vigorous pallet-exchange program with freight carriers resulting in $15,000 annual savings.

- Substantially increased production output, improved on-time delivery through formal work schedule processes, and initiatives to reduce line changeover times.

- Defined, directed, and trained 2 departments on specific procedures compliant with ISO 9000 standards for issuing, maintaining & tracking part numbers; reduced duplications & minimized incorrect identifiers for material part numbers.

- Reduced finished goods inventory by 90% & achieved 98% on time delivery through capacity planning and make to order policy utilizing MRP/ERP analysis. Established Demand Driven Materials Planning.

- Technology Implementation/Capital Expansion. Major player in improving efficiency by implementing

new computerized systems, including pick location sequencing, bar code location, UPS/FedEx/RPS automatic shipping, and conversion to SAP.

Project manager over purchase and set up of off-site facility used to house materials department, including supply, store, shipping & receiving, logistics, transportation, import-export, and purchasing departments.

- Certification/Training. Green & Black belt earned in Six Sigma; CPIM certification courses: Master

Planning of Resources; American Production and Inventory Control (APICS) certification.

EDUCATION

B.A. magna cum laude, Economics/Statistics, University of Michigan, Ann Arbor, Michigan, April 1979.

TECHNICAL SKILLS

Windows 7; Microsoft Office Suites (Word, Excel, Access, PowerPoint, Outlook, Project Manager); Minitab; CNC; Enovia; CATIA (3D Design); SolidWorks; TeamCenter 8, 10.3; Visiprise; Fast Risk Analysis & DES Software (Simio, Simevent, Simulink); Java; CMM software & equipment; @Risk, Oracle PRA/Pertmaster; AS/400; SAP; Focus; NetSuite, MRP& II; EVO, ERP; Master Production Scheduling (MPS); Oracle; JD Edwards; Minitab; Visio; Lotus; AutoCAD; CAD; DOORS; Maximo; Millipore Testing Software; Gensuite; WebEx; Laser Testing Equipment; Welding Equipment (including Laser); 3D Printers. PMP. CQE.

REFERENCES: References will be furnished upon request.

PERSONAL

Interests: writing, golf, tennis, scuba diving, reading, films, woodwork. Married: Wife: Kelly Lea (Spencer) Lupinski.

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