Engineer Plant
Resume:
Dan Antonios
Fort Wayne IN 46804
acvee2@r.postjobfree.com
Confident, self-motivated professional with proven ability to improve manufacturing operations surpassing corporate objectives. Proficient in Implementing the Toyota Production System working on the plant floor with the operators getting them involved to drive & sustain needed performance.
My Technical Aluminum Extrusion Capability:
Completed Alcoa University Aluminum Metallurgy and Continuous Improvement Programs. Continually studying Extrusion Technology and The Metallurgy of Aluminum. Technically I do well in Aluminum Welding Application.
Completed Five Aluminum Extrusion Technology Seminars in Extrusion Technology and Simulation.
Worked on several Aluminum extrusion projects. “Class Room and Actual Field Implementation." wrote a Comprehensive Technical Aluminum Extrusion Best Practice Manual.
Developed an extrusion press practice for 6061 Alloy Quenching with 100% air and achievingT-6 after aging.
Developed a 5 hour artificial age cycle for 6061 & 6063 T-6.
Developed a 6XXX alloy to eliminate undersurface defect in extrusion.
Capable of optimizing the Extrusion Process to Maximize Recovery, and Increase Die life by 30%.
Developed New Die Design Improving extrusion surface finish and reducing scrap by 27%.
Through Die Design I Established Extrusion Process Eliminating post Anodizing Flow Lines, Improve Extrusion Surface Quality.
Developed best application procedures for Aluminum Extrusion Anodizing, Paint "Wet and Powder, Thermal fill, Fabrication and Forming.
Improved the performance of an Anodized line and introduced an Alternative Anodizing Process for Bright Dip applications.
Completed several Aluminum Extrusion Forming projects Document & Implement Forming of Aluminum Extrusion best practice.
Career Accomplishment in Lean Manufacturing & Continuous Improvements:
1)Establish and Execute Business Plans, Involving Process Team Leaders to Analyze Production Costs, Product Quality Promoting Manufacturing Excellence. Results: enhance profit by 30%.
2)Create a Centralized Training Function to Support Core Competence. Implementing Lean Manufacturing and Lead the Change Linking Organizational Strategy to Action.
3)Completed 73 Continuous Improvements Business Cases: Results in reducing Manufacturing Cost by 27% in Each Case.
4)It is a must to Operate with an Action Plan and Review Plant Performance daily.
5)Implement Program Management System Initiate Project Road Map from the Technology/ Development Stage taking each project through the Gate Review Process, Project Validation & Customer Approval. Achieving Six Sigma Performances.
6)Successfully Completed Kaizen Workshop Converting Traditional Extrusion Work Cell to the Lean Concept, establishing synergy between Manufacturing, Process Engineering, Quality and The Customer.
7)Introduced Advanced Manufacturing Programs Increasing Productivity by 25%.
8)Pioneered house account principal to maintain competitive edge in a tough market without sacrificing margins.
Customer Focus: Implement cooperative Supply Chain system with the customer against the competition Simply By
Understanding the total set of customer needs.
Maintain manufacturing process valued by the customer, from The Moment an Order is received to the point when it’s shipped.
Knowledge based process to match customer needs with internal capabilities, Achieving Competitive advantage
EDUCATIONAL ACHIEVEMENTS
Three Years of Chemical Engineering, Accounting and Economics at Cleveland State University.
One Year at Kent State University Studying Coating Technology.
Completed Advanced Aluminum Anodizing Class
Aluminum Casting I Completed two Solidification Course.
Ten Years implementing Six Sigma Lean Manufacturing Programs.
Fifteen Years Automotive Program Management System and Project Management.
Eight years Implementing ISO 9001, QS 9000 & ISO/TS 16949.
Completed Paulson & Zipps Plastic Extrusion, Injection and Blow Molding Training Program.
Wrote & Implemented a Comprehensive Best Practice Manual for Six Sigma and Lean Manufacturing.
Studying Advanced Manufacturing Programs, Customer and Supply Chain Management. In 2012 completed classes at Perdue University in operation analysis / improving profits through continual project implementation.
ASQ Certified Six Sigma Black Belt.
Through Executive Education I Studied the Toyota Production System in Toyoda City Japan
SAPA: St Augustine Florida March2016 to June 2016: Plant Engineer
Throughout The Facility completed the following project: Fabrication Department upgrade controls on 3 punch presses. Added two new Buildings for Shipping Department, Extrusion Operation press # 1 & 5 mechanical and control replacing what is needed, also ordered all needed spare parts for each press line.
Alexandria Industries Indianapolis Indiana April 2015 to March 2016: Die Shop Manager /Process Engineer
The Project to Convert an11” Aluminum Extrusion Press to 10”. Engineered Aluminum Extrusion tooling for 400 plus new Profiles launched all of them from initial stage all the way through mass production. I had to make very small correction to 4 profiles.
Completed all needed Die Shop improvements making it a very efficient die shop, manned by 3 die shop technicians supporting a Seven per Day Week extrusion operation.
For The Extrusion Operation I wrote and implemented P.M. Programs. Also for machining and critical mill finish Applications developed two alloys 6061 and 6063
Clean and Organized Shipping and Packing Department establishing a Kan Ban system integrated with a supply chain so all Shipping and Packing consumables managed by each supplier.
Worked with our tooling supplier to Design a total of 4 new concepts of extrusion tooling to reduce scrap by 1.5% one of tooling design I will presented at ET 2016. Working on developing extrusion tooling to reduce cost by about 2% .
SAPA: St Augustine Florida June 2014 to April 2015: Process Engineer
Responsible for the die shop and extrusion improvement at the plant floor, also work very closely with maintenance dept. upgrading / setting up PM programs for 3 press operation.
With support of outside contractors completed the following equipment repairs:
Repair log oven on P-5. Repair age ovens on P-5 and P-4
Worked with saw blades supplier establishing almost Burr free operation at each finishing saw.
Extrusion improvements: Used two dies per month program improving recovery and extrudability for a total 98 profiles implement green folder program to all new profiles establishing a capable extrusion recipe for each profile
Engaged Press lead with blue folder improvement program results 27 recipes developed by press leads Engineered and placed in circulation new extrusion rack that made it possible to eliminate 4 packing jobs. Installing new press controls to improve the extrusion process for complex profiles. Working with tool makers taking on complex extrusion profiles
Extruders Inc Wylie Texas Sept 2013 to June 2014: Process Engineer
Organized Maintenance Dept. established MRO stores staffed with one PM Planner.
Repaired Major Process Equipment on both paint lines.
Responsibility for the operation to 3 UBE Presses restoring them to original Conditions Adding Closed Loop Extrusion PLC System.
Effectively Evaluated LCI Extrusion Facility, Responsible for closing the plant, moving what is needed and installing it at the Wylie Texas extrusion plant.
Nanshan America Lafayette Indiana February 2012 to Sept 2013: Project Engineer
Wrote ISO 9001 -2008 Quality Manual, Completed Gap analysis with our ISO Registrar.
Purchased and set up equipments required for Mechanical Testing and Profile Measurement.
Completed evaluation for the testing requirements to set up a Metallurgical testing lab for the Cast house. Purchased Order Issued My next step to receive and setup all of the testing equipments.
Wrote an extrusion best practice manual integrating the die shop as part of the extrusion process.
Completed Cast house best practice manual integrating the casting operation with the extrusion process optimizing Total Plant Recovery.
Set up EPCIS, purchased, installed required equipment for each work cell including shipping.
Applied engineering principles to Mistake proofing profile Stacker and de-stacker at each press
Formulated Specific Chemistries for 6XXX and 5XXX Alloy.
Took a leader ship role supporting Nanshan effort to acquire new customers “Would like to have a conversation with you about my accomplishments in this area.”
LCI Extrusion Elkhart Indiana Position June 2010 to February 2012:
Hands approach providing leadership and effectively taken on the task to install and start up 3 press operations and a new powder coat line. Synchronized the extrusion Process from the press through paint, shipping, controlling quality at each work cell,
Area Of responsibility and Accomplishments:
1.Completed engineering to all extrusion tooling for each press and installed a die shop.
2.Completed the Installed and Start up of two artificial Age oven processing.
3.Completed the install and Qualification of Paint line pretreatment processing.
4.Support maintenance team in the start up and implementation of a PM Program.
5.Completed die qualification and approval for 20 dies.
6.Completed the installation of Press # 1 fully staffed and extruding on two shifts.
7.Responsible for the Ongoing installation of press # 2
8.Completed 60% of the installation of Press # 3.
9.Completed the installation of the powder coating line.
Received A Person that goes above and beyond Award from LCI
Frontier Aluminum Corp. Extrusion Process Owner November 2009 to June 30 2010
Provide leadership on the plant floor effectively implementing quality system at the source of each work cell. Supported the addition of new Value add extrusion process.
Area Of responsibility:
Plant # 1: One press operation, Paint line, Fabrication and main shipping Department.
Plant # 2 Two Press operation Packing department and full truck load shipping function.
Tecate Plant in México: Anodize line, Thermal Fill process and Buffing Operation.
Complete Responsibility for three Press extrusion operations and Scheduling.
Implementing Lean Manufacturing and Continuous Improvement Programs.
Responsible for die shop function, Process engineering group and the Quality department.
Support sales Department to secure new customers.
Accountable for cost control programs keeping our competitive edge in a tough extrusion market.
Accomplishments:
Re-organized extrusion process flow for the 7”, 8”& 9” press establishing synchronized flow between
Plant #1, Plant # 2 and the Tecate Plant in México with outstanding results.
Improved the Thermal Fill process results material savings of $0.05 saving per lbs
Worked Equipment Supplier to installed extrusion buffing Process at the Tecate plant.
Completed all of the necessary work to install new alternative for Bright dip application.
Improved the operation of the anodized line at the Tecate Plant.
Worked with Maintenance team to implement extrusion Preventative Maintenance Program.
Start a bench mark program for the 7”, 8” & 9” presses.
Converted extrusion profiles from traditional pack and ship process to pack and ship off the press.
Initiated daily pitch & quality programs at each extrusion press eliminating traditional supervisory position.
Established MRO stores / Kan Ban Stations eliminating the purchasing function a savings of $50,000per year.
Crystal Finishing System Inc. Extrusion Process Owner October 2008 to November 2009.
Complete Responsibility for Three Press extrusion operations and Scheduling of the Department.
Implementing Lean Manufacturing and Continuous Improvement Programs.
Responsible for die shop function, Process engineering group and the Quality department.
Support sales & marketing to secure new customers.
Accountable for cost control programs keeping our competitive edge in a tough extrusion market.
Accomplishments:
Re-organized extrusion process flow for the 7” & 8” press work cell.
Worked with Maintenance team to implement extrusion operation Preventative Maintenance Program.
Engineered & introduced new die and press tooling for complex shapes able to extrude with great results.
Customer I had previously worked with I secured their extrusion with Crystal Finishing System.
Installed protective silicon bumpers to extrusion racks to reduce handling damage and load shifting.
Introducing advanced tooling technology for multi hole thin profiles increasing productivity by 9%.
Start a bench mark program for the 7”, 8” & 10” presses.
Controlled the extrusion process and introducing new die designs we converted level 4 dies to level 2.
Start the implementation of 7’S Program.
Enrolled in company sponsored customer service and lean manufacturing programs, class room training and implementing what I have learned on the plant floor.
Implemented die management and evaluation achieving 90 plus percent first time extruding out of the box.
Reduce die shop staff by four and successfully tied the die shop with the extrusion operation.
Converted twenty-one profiles from traditional pack and ship process to pack and ship off the press.
Initiated daily pitch & quality programs at each extrusion press eliminating traditional supervisory position.
Franklin Aluminum Co. Extrusion Process Owner: July 2006 to October 2008
Complete Responsibility for the Operation of the Extrusion Department.
Implementing Lean Manufacturing and Continuous Improvement Programs.
Responsible for the Engineering Function of Press Tooling and Die Design.
Accountable for new Product Launches, and Extrusion Die Management.
Support Plant Process Engineers & Quality Engineers.
Accomplishments:
Completed The Implementation of 7'S Program.
Re-Organized The Extrusion Process Flow.
Organized & Implement Press Operation Preventative Maintenance Program.
Established Extrusion Tooling MRO Stores.
Start The Implementation of Six Sigma Lean Manufacturing Programs Using The Toyota Production System.
Completed The Engineering of Press Tooling, Extrusion Best Practice to meet Customer Quality Requirements for Chrome, Anodized and Painted Extrusions. Results: Scrap decrease by 25%.
Developed Extrusion Procedures achieving required TYE controlling Spring Back in The Forming Process.
Successfully Completed Four Kaizen Workshop Converting a Traditional Work Cell to The Lean Concept. Results: What was produced in seven days now can be completed in four days.
Engineered New Extrusion Racks That made it Possible to Minimize Handling Damage.
Introducing Advanced Tooling Technology to Increase Productivity by 25%.
Started a Bench Marking Program for The Extrusion Process.
Reduce The Work Cell at The Finishing Saw by One Operator per Shift.
Completed Two D.O.E. Results: Potential 14% Increase in Product Recovery.
By Controlling Extrusion Parameters and Introducing New Die Design. Increase Die Life by 30%.
Indalex Aluminum Solutions: March 2003 to July 2006.
Continuous Improvement Engineer Responsible for the Quality Department at the Kokomo & Connersville Plant, implementing Continuous Improvement and Lean Manufacturing Programs at Four of Indalex Extrusion Facilities. Also in Part supporting other Indalex Plants with Product Launches, I was The Single Point of Accountability to Five of Indalex's Major Customers.
Projects Completed at The Kokomo Plant:
Completed 5’S Plant Clean up and Re-Organized the Manufacturing Process Flow for the Extrusion Process, Fabrication and Packing Departments.
Organized The Maintenance Department & Opened MRO Stores.
Implemented Lean MFG Programs using The Toyota Production System as Overarching Principles.
Completed ISO9001:2000 Certification and Registration.
Faultlessly Launched: Utility Trailer, Featherlite, Great Dane, and Midwest Industries extrusions programs.
Successfully Completed The Implementation of SMED in The Fab Department.
Organized, Stream lined packing department establishing a super market and Kan Ban for all Packing supplies.
Completed a Kan-Ban Inventory System to Service The Depot Program.
Projects Completed at The Elkhart Plant:
Completed ISO9001:2000 Certification and Registration.
Faultlessly Completed The GMT 800 Profile Launch for Magna Corp.
Engineered New Packing Racks That made it Possible to Eliminate One Packing Work Cell.
Completed Four Kaizen Workshop Converting The Metal Saw Work Cell to The Lean Concept. Results: What was produced in five days now it takes three days with four fewer operators.
Developed in House Ultrasonic Testing Process for Specialty Rod and Bar Profiles.
Projects Completed at The Connersville Plant:
I worked with The Technical and Engineering group to complete up grade and install new equipment.
Completed ISO9001:2000 Certification and Registration.
Stream lined Extrusion process to service Heavy Transportation extrusion market.
Implemented Lesson learned from the Kokomo packing line at Connersville with Great Results.
Completed the launch for Wabash National extrusion program.
Trained Quality Personnel to test Aluminum extrusion per set ASTM Standard.
Worked with press lead and die shop to improve the extrusion process, within a few weeks, both departments functioned as one unit.
Projects Completed at The Mississauga Plant:
Support The Launch of GM Engine Cradle Profiles, developed Extrusion Best Practice to achieve Special TYE Requirements for The GM Engine Cradle.
Alcoa Automotive Auburn Indiana: Process Engineer / Q.A. Supervisor June 2002, to March 2003.
Restructured the Quality Department and implemented the Toyota Manufacturing and Quality System.
Implement Six Sigma Lean Manufacturing Program, & administered structured problem solving and root cause analysis targeting defect free configuration using run chart.
Took a Leader ship roll with Delphi, General Motors to regain preferred supplier status. Exiting CSI & CSII for the Engine Cradle and Corvette Platform.
Successfully launch The Magna Platform, Wilkinson Platform & the Toyota 483 Bumper.
Completed Alcoa, ABS University for Continuous Improvement Programs and Aluminum Metallurgy classes for 6XXX, 5XXX, 7XXX and 2XXX Alloy.
I took a leadership role in developing coating for forged wheels, Aluminum extrusions at the Kokomo Extrusion Plant and Alcoa Cleveland.
Developed best application procedures for Aluminum Extrusion Anodizing, Paint "Wet and Powder, Thermal fill, Fabrication and Forming.
Kautex Textron Avilla Indiana: Manufacturing Process Engineer June 2000, to June 2002.
Manage and direct all of the process Engineering Functions for the Mitsubishi Manufacturing/Assembly Platform. Accountable for the implementation of Six Sigma Lean Manufacturing Programs evaluating assembly stations cycle time study for each station. Engineered and installed auto deflash station for the blow molding press result: reduction of press cycle time by 33 second and reassigned 3 operators off the Mitsubishi line.
Responsible for writing and administering of: DFEMA, PFEMA, CONTROL PLAN, and operator instruction with visual aide. I wrote a blow molding best practice manual, and installed PWDS to control material cost.
Took a great initiative in training manufacturing personnel to identify customer requirements and meet set objectives through structured problem solving and root cause analysis using run chart.
Successfully completed all of the required trials from the I.S. stage to the Quality confirmation stage and the engineering/design Layout of all assembly stations for the Toyota 500N platform.
Successfully completed the engineering and down line assembly process for the Toyota 483 Platform.
Launched the following programs GMT800, GMT610 and GMT500.
Twenty plus years career within the same group in the Manufacturing and Application of Industrial Coating.
RPM: 1993 to 2000
As a Plant Manager successfully operated a variable sale driven manufacturing and capital budget exceeding set KPI’s.
Established an inventory control system to measure inventory turns of finished goods and raw material and eliminate stock out at all satellite warehouses and distribution centers.
Engineered and installed new process increasing productivity by 13%.
Implement packaging material supply program to control cost of goods sold in the first year we saved 2%
Responsible for all regulatory DOT regulation and all necessary permitting to operate the manufacturing plant.
Implement six sigma continuous improvement Projects / Kaizen to establish synergy between Manufacturing, Process Engineering, Quality and The Customer.
Pioneered house account principal to maintain competitive edge in a tough market without sacrificing margins.
At the manufacturing floor I managed with a flat structure Plant Manager, Quality Manager and a work force.
Man-Gill Group: 1982 to 1993
As a Plant Manager I was directly responsible for Manufacturing Operation and to the Development of Operating Strategies, Cost analysis and Improve Plant Process.
Identified customer needs designed a total quality management program increasing Man-Gill visibility through strategic monthly visits with customers. Within 18 month return dropped by 7%.
Engineered and installed a new paint additive plant creating a new Customer Base.” ROI of 30 month.”
Responsible for the design and implementation of training programs so all employees are able to perform all aspect of their job in accordance with company standards for safety, quality and productivity. Meeting stringent requirements of 1.5% adjustment cost on all products.
Played a major role in the development of coating for forged wheels, Aluminum extrusions at the Kokomo Extrusion Plant and Alcoa Cleveland.
Successfully implemented a work cell concept eliminating the traditional production supervisor position.
Acquired necessary technical training and experience for OSHA and EPA regulations.
Mameco Group: 1979 to1982
Managed and directed all manufacturing and scheduling functions. I planned production activities and established priorities to optimize output and control cost factors.
Introduced new monitoring procedures for the batching system that reduce two hours of processing per batch.
Installed flow meters to cut gas consumption to all plant boilers by 25%.
Designed and installed a 10,000 gallon water recovery system to all plant reactors to save $12,000 per month.
Accountable for the batch process worked closely with R&D, Quality Control and Plant Leads to solve manufacturing problems in a quality circle forum increasing yield by 10%.
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