Customer Service Lean Manufacturing
Resume:
Chad Lusty
Elkhart, Indiana 46514
Cell: 903-***-****
Email: *********@*****.***
Over 30 years Foundry Management experience dedicated to achieving safety, cost-control, profitability and outstanding customer service. Extensive background in “Premium Engineered” aluminum and magnesium casting, including “MIL-A-21180” military grade with focus on the Aerospace and Automotive Industries. Knowledge of sand, tilt pour permanent mold, squeeze mold, and low pressure permanent mold casting processes. Trained in metal preparation, metallurgy, chemistry, lab testing procedures, and equipment design. Working knowledge of gas-fired reverbatory and silicon carbide crucible type (gas fired, and electric) furnaces, and low pressure electric “Dimo” furnaces. Experience in core make, cleaning, penetrant(NDT), and maintenance departments. Reliable professional with exceptional analytical, organizational and people skills. Strong personal ethics and integrity. Skilled in working harmoniously with personnel from diverse socioeconomic and cultural backgrounds. Good conflict-resolution skills. Work well under pressure and deadlines. Highly organized team-builder with strong leadership experience. Excellent communicator seeking a challenging position utilizing current skills and abilities.
Experience
Foundry Superintendent 9/2014 - 4/2016
Chassix, Bristol, Indiana
(Automotive Foundry Employing 900 Nonunion Associates)
Responsible for all Production Supervisors and daily production schedule.
Reviewed all mold procedures.
Set priorities and distributed work force to attain production goals.
Utilized Launder System to deliver molten metals to production cells.
Experienced in robotic production to reduce manpower costs and improve safety compliance.
Originally hired as Supervisor; promoted to Foundry Superintendent.
Maintained low employee turnover through effective motivational management.
Melt & Molding Manager 1/2014 - 8/2014
Denison Industries, Denison, Texas
(Commercial/Aerospace Foundry Employing 100 Nonunion Associates)
Scheduled production activities of first and second shift Mold/Melt Departments.
Reviewed all mold/melt procedures.
Introduced Argon melt preparation to sand pour melt processing, greatly improving casting quality.
Projects Include:
Exhaust housing for rocket drive for unmanned Space Shuttle.
Production Supervisor 2013 - 2014
Wellman Dynamics, Creston, Iowa
(Aerospace Foundry Employing 500 Union Associates)
Coordinated the daily production activities of the second shift airset and isocure sand core lines as well as the melt/pour, shakeout/bake out, support, utility, and maintenance departments.
Reorganized core make work instructions, reducing time needed to find proper instruction.
Implemented continuous improvement project, using lean manufacturing techniques, to give just in time chill delivery to production lines.
Responsible for hiring, training, promotion, and discipline of 41 union Associates.
Melt & Molding Production Supervisor 2001 - 2012
CPP/Hitchcock Industries, Bloomington, Minnesota
(Aerospace Foundry Employing 500 Nonunion Associates)
Coordinated daily production activities of aluminum and magnesium melt/pour, and shakeout/bake out departments. Also responsible for reclaim sand system.
Ordered all raw materials for melt departments. Working with quality and purchasing departments, set up guidelines for these materials and selected suppliers accordingly.
Authored or reviewed all melt/pour processes.
Active member of “Refit Team” responsible for the remodel of both melt/pour areas.
Worked with engineering and maintenance departments to successfully design and build Chlorine/Argon mixing system as well as a rotary degassing unit that reverses direction before a “vortex” is created, improving melt quality.
Used lean manufacturing techniques to reduce raw material inventory by 60%.
Worked with Plant Metallurgist to set up and teach “Melting 101” classes for training purposes.
Virtually eliminated melt related scrap.
Responsible for hiring, training, promotion, and discipline 32 nonunion Associates.
Originally hired as Melt Floor Associate; promoted to Melt & Molding Production Supervisor within 2 months.
Projects Include:
Prototype "Lucy" project for unmanned Space Shuttle.
Battery casings for manned Space Shuttle.
Prototype project for Osprey gearboxes.
Aerospace Castings for: Aerospace; Boeing, Lockheed Martin, Rolls Royce, Raytheon, Sikorsky, GE.
Automotive Castings for: GM, Ford, Chrysler, BMW, Harley Davidson.
Melt & Molding Production Supervisor 1986 - 2001
Progress Casting Group, Plymouth, Minnesota
(Aerospace/Commercial Foundry Employing 300 Union Associates)
Coordinated daily production activities of aluminum melt/pour department over 3 shifts.
Ordered all raw materials for melt department.
Authored or reviewed all melt/pour processes.
Active member of expansion project. Reviewed and helped plan layout of plant addition as well as researching new equipment.
Responsible for hiring, training, promotion, and discipline of 22 union Associates.
Originally hired as Furnace Tender; promoted to Lab Technician; promoted to Melt & Molding Production Supervisor.
Education and Credentials
Advanced Training:
Medical Based Lab Testing
St. Paul Technical Institute, St. Paul, Minnesota
Focus on Chemistry & Lab Testing Procedures.
Management - Employers Association, Plymouth, Minnesota
Molten Metal Processing & Foundry Safety
Cast Metal Institute, Schaumburg, Illinois
SPC, Lean Manufacturing, FMEA, Kaizen (The Toyota Way), 5S & Sigma 6 Disciplines
ISO, NADCAP, HAZMAT Rules & Regulations
Magnesium Fire Suppression - Bloomington Fire Department
Computer skills include ADP, Microsoft Office (Outlook, Word, Excel & PowerPoint).
High School Diploma - Lafayette High School, Red Lake Falls, Minnesota 1985
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