Engineer Manager
Resume:
Antonio Erazo
Frisco, TX **035
E-mail: *******@***.***, Cell: 504-***-**** http://www.linkedin.com/pub/antonio-erazo/18/30a/78
SUMMARY
Creative, organized and Senior Engineering professional with significant experience improving processes in the manufacturing industry. Special expertise includes cost improvement strategies and implementation, productivity, work design, and lean manufacturing. Open objective management style that leads by example, honesty, and clear communication.
Strong record of documented success and demonstrated strengths in:
Lean Manufacturing & Six Sigma.
ISO 9001-2008.
Plant Productivity and Optimization.
Design Fixtures, Jigs and Shop Floor Aids.
Statistical Process Control (SPC).
Waste and Cost Reduction Techniques .
Metal Fabrication Processes, Sheet Metal, CNC Machining, Welding Robotics, Powder Paint, etc.
Project Management.
Cellular Plant Layout Design.
Manufacturing Process Standards (MPS).
Solid Works, AutoCAD, Inventor and Pro-E Drafting Platforms.
Process Design and Improvements.
Tooling Design.
SAP, JDE MRP Systems.
PROFESSIONAL EXPERIENCE
RUSKIN/ JOHNSON CONTROLS INC (Merging Companies), Dallas, TX 2015 - April 2016
Senior Manufacturing Engineer.
Responsible for the energetic role of implementing three Champions, Value Stream Flow, DFMA and Energy, also in charge of all manufacturing processes of HVAC for the facility.
Changed the floor layout process of the sheet metal departments with turret punches and press brake operations to reduce walking waste time, bottle necks, WIP, and closer align these operations with paint, pre assembly and assembly increasing productivity by 20%.
Created a feasibility study project to change turret punches for laser cutting equipment resulting in substantial savings of material consumption, tooling and head count reduction generating a ROI of 40%.
Designed using Inventor a Kanban replenishment cart for high volume sheet metal parts to be in strategic POU’s that reduced walking waste time and distance by 20%.
Lead Kaizen event to find out current VSM, and strategically analyzed it to establish future VSM with savings averaging 25% in process time.
Changed the assembly layout to increase productivity for the production expansion of the biggest units ERV and EVT, by re-arranging the process sequence and adding resources to capacity planning to meet the challenging goal to quadruple sales.
Lead Kaizen event implementing six assembly conveyor lines equipped with a one piece flow motorized system, and applied line balancing to synchronize work centers increasing by 20% assembly, packing and shipping time.
Resolved all paint technical related quality control issues by upgrading the powder paint oven burners to a more reliable system, maintaining high temperatures and cure parts evenly reducing adhesion issues bottle necks to zero.
Served as liaison between design and manufacturing engineering to establish controls, audits and easy to make parts and prototypes for future production with potential savings using DFMA techniques.
Lead Kaizen event creating a pre- assembly area for building sub-assemblies and kitting all parts going to the assembly lines resulting in a 25 % reduction of labor cost.
Acted as PMP for moving three main production areas to a new building by, scheduling and monitoring activities in a Gantt chart, designing the production process, and dealt with vendors reducing cost of new purchased equipment by $500K.
COMMSCOPE/ANDREW LLC, Dallas, TX 2013 – 2015
Process Engineer.
In charge of all manufacturing processes, designed and created Manufacturing Process Standards of all the manufacturing equipment with visual work instructions on how to operate safely all sheet metal machines, designed in Solid Works different types of crates to speed up packing and shipping products.
In charge of processing in SAP all Engineering Changes Notification (ECN's) making sure that these changes are feasible for manufacturing.
Design fixtures and jigs in Solid Works to run new parts on the welding robotic area, increasing productivity by 15%.
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In charge of all lean manufacturing projects; started with 6S re-arranging and organizing all production stations saving 10% of the production time, designed a current VSM and decreased cycle time in the kitting area by 15%, created a one piece flow system and line balanced the process of copper parts produced by the turrets machines reducing process time by 20%.
Studied many parts to use JIT techniques and created a schedule to deliver parts on time coordinated with suppliers on a by- weekly basis rather than weekly reducing carrying inventory cost of purchased parts by 50%.
Made SPC data sheets to gather and reduce parts out of tolerance for re-work, established a root cause analysis solution creating saving of 25% in labor cost.
STANLEY BLACK & DECKER, Dallas, TX 6 Months Contract Mar 2013 – Aug 2013
Process Engineer.
In charge of BOM's, routings, CNC equipment, overseeing machinery, tools and spare parts purchase for this equipment, designed fixtures to run parts on CNC machines, responsible for ECN’s, time & motion studies, ergonomics, line balancing and lean manufacturing Improvements in the socket area.
Created BOM’s, routings and ECN’s to change the production process from hot forge to cold forge to reduce cost, quality defects, rework and waste.
To avoid purchasing new equipment, re-engineered, designed in Pro-E and made parts for lathe machines that were down to fix them, and put them back to use, for very substantial savings.
Designed fixtures and shop floor aids in Pro-E increasing productivity by 15% in the small and large socket area.
Reduced 20 % of production time of parts in the socket area by grouping parts and studying cycle time per operation, and arranging CNC machines in a U shape cell to make all steps required in one station rather than three to finish a product.
Developed and conducted a 6S project Kaizen event in the CNC machining area, increasing productivity more than 10%.
STEWART & STEVENSON LLC, Start up Facility, Killeen TX. 2012 – 2013
Senior Industrial Engineer.
In charge of all Industrial Engineering areas, time studies, line balancing, one piece flow, operations research matrix to optimize assembly, ergonomics, BOM’s, routings, efficiency and productivity, responsible for supervising the maintenance employees. Provided guidance to other manufacturing engineers.
Reduced walking waste distance by creating a layout in AutoCAD that compacted all areas among departments on the shop floor reflecting an increase of efficiency by 20%, and at the same time generating enough extra floor space to create a dual production process.
Design and make cart fixtures in Autodesk Inventor to be able to transport on the shop floor and to vendors engines and transmissions of different truck brands reducing safety issues and increasing productivity among work centers by 25 %.
Avoided downtime in the process by designing and constructing steel sheet sheds to protect exposed production equipment against bad weather.
Lead a Kaizen event creating a Kanban and a kitting area in the warehouse to rapidly serve and replenish parts to the axle, transmission, and engine work stations reducing work flow issues to zero.
TEXTRON MARINE AND LAND SYSTEMS, New Orleans, LA 2010 - 2012
Manufacturing Engineer /Tooling Engineer.
Designed fixtures, jigs, shop floor aids and any tooling for all Armor Security Vehicles from concept to implementation to speed up productivity and increase efficiency in the production floor. Conducted feasibility studies to change the welding manufacturing processes from manual to robotics and increased productivity by 500%. Reverse engineer tools using Solid Works to develop, maintain and outsource major welding fixtures for labor cost reduction.
Designed and created a fixture to weld the Front Differential Assembly of the TAPV Canadian armor security vehicle, increasing productivity by 15 %.
Developed a tool to weld appliqués and studs on ASV armor security vehicles, increasing the welder’s efficiency by 20%.
Designed from concept to implementation a universal front and rear axle mounting fixture for all different armor security vehicles, increasing productivity in that area by 20%.
Designed and created a mobile ballistic door seam tool fixture for handling large parts in the blast and paint area, increasing operator’s efficiency by 20%, and in addition improving ergonomics for the operators.
Designed a turret flip over fixture to be used with a mechanized system to be able to outfit turrets with accessories in a safer way, and at the same time improved ergonomics and operator’s efficiency by 25%.
Reverse engineer 40mm, and 50 caliber aluminum calibration guns to be use as mockups needed to improve, adjust and synchronize accurate aiming of the turret’s machine guns, substantially improving ergonomics in this work cell.
Reverse engineer for improvement and accuracy the engine and t-case mount location fixture in all ANA, ASV, TAPV variants models, increasing productivity in this station by more than 20%.
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OSHKOSH TRUCK CORPORATION, Start up Facility, Killeen, TX 2008 – 2010
Senior Process Engineer.
Designed and created work instructions, assembly process sequence, production parts routings and BOM’s for the weld shop, paint shop, and assembly line areas. Conducted time and motion studies and line balancing of the process based on variable takt
time. Used lean manufacturing techniques for waste reduction and to increase plant’s throughput. Supervised the maintenance supervisor and maintenance helpers.
Designed in AutoCAD the start up facility process layout to produce Army and/or Marine truck cabins based on knowledge of the metal fabrication process, ability to visualize spatial and time requirements, and knowledge of the product.
Created a flawless production process generating an Army and/or Marine truck cabin every 2.25 Hrs by simplifying work instructions, using visual aids and easy schematics to read in the whole process.
Increased the operator’s efficiency from 70% to 98% by identifying room for improvement, evaluating the current process, and designing a one piece flow that “pulled” work as needed instead of a “push” process.
Significantly decreased the amount of production labor costs from 130 to 85 hours per cab, by implementing a line balancing manufacturing process in the whole facility.
Decreased to “0” hours the down time of the zinc phosphate area by investigating with outside vendors to identify and correct issues within the process.
Reduced the yearly amount of spare parts by 60% in the zinc phosphate area by studying the maintenance manuals and accurately estimating quantity and use frequency.
PELLERIN MILNOR CORPORATION, New Orleans, LA. 2001 - 2008
Senior Industrial Engineer.
In charge of factory-wide improvements in efficiency and productivity. Conducted feasibility studies to justify investment in capital equipment, laser cutting machines and CNC machining. Designed fixtures and jigs using Pro-Engineer and AutoCAD.
Reduced 35% of labor costs by utilizing lean manufacturing techniques in the assembly area including Kanban, JIT, one piece flow and line balancing, and then redesigning the work tables ergonomically and cross trained the operators.
Reduced roll part re-works and defects by 30% by designing templates for the roll machine operators to make parts to print.
Implemented a new layout in the electric shop and changed manufacturing system to a one piece flow, and re-configured the workstations as work cells increasing productivity by 25%.
Increased productivity by 15% through the use of 6S techniques arranging, and splitting the powder paint line into a standardized layout which separated the loading from the unloading area, organizing the process flow.
Decreased the amount of labor hours assembling the biggest dryers from 120 to 75 by changing the layout, the work flow, and the assembly process sequence.
Using six sigma methodologies and root cause analysis was able to eliminate 50% of defects and rework, by identifying problem parts and investigating and fixing the issues that did not add any value to the products.
Minimized worker fatigue and raised efficiency from 75% to 95% by compressing the layout format in the bearing house assembly area.
Studied different welding assemblies and reduced the amount of welding material from 1/4” to 3/16” gage, a potentially large reduction in material cost.
FRUIT OF THE LOOM (FTL), Zip El Porvenir, Honduras C.A 1997 – 2000
Assistant Plant Manager & Operations Manager.
Responsible for all operations of the largest FTL facility in Latin America with 4,000 operators, including production, lean manufacturing events, import and export containers and supervision of five direct reports, Production Manager, Quality Manager, Manufacturing Manager, Logistic Manager & Warehouse Manager. By a combination of good team work I was able to strategically pack 15% more dozens of product in every box and reduced shipping cost to USA. I was also able to increase our production rate by 20% changing the manufacturing process from progressive bulk to a one piece flow system.
EDUCATION
MBA Economics, 3.67 GPA, Nova Southeastern University, Ft. Lauderdale, FL
BS, Industrial Engineering, Jose Cecilio Del Valle Private University, Tegucigalpa, Honduras
3 years Industrial Engineering courses, Lamar University, Beaumont, TX
SEMINARS
Lean Manufacturing Principles & Six Sigma, MEPOL, New Orleans, LA
Techniques for Investment Projects, United Nations Org., SPS Honduras
Budgetary Control, KPMG Peat Marwick Mitchell & Co. Panama City, Panamá
C. A. Symposium of Food Processing, Tech Institute of C.R., Costa Rica.
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