Engineer Quality

JAMES “JOSH” BAYNE

937-***-**** • Piqua, OH (Relocating to within 50 miles of Shelbyville, TN) • **********@*****.***

MANUFACTURING OPERATIONS / PRODUCTION MANAGER

Results-orientated hands-on manufacturing leader with a solid record of increased profitability, customer focus, plant-wide safety, improving line efficiencies, quality output, supporting team goals, cost reduction, and motivating strong workforces to achieve organizational objectives.

AUTOMOTIVE TIER I & II • MANUFACTURING • STAMPING • FABRICATION • ROBOTICS

• Team Building • Quality Assurance • TS 16949, ISO 14001 / 9001

• Strategic Planning • Cross Training • Lean Manufacturing / 5S / Kaizen

• Mentoring / Retention • GD&T • Root Cause Analysis

• Continuous Improvement • MIG / TIG Welding • MRP / EDI / Scheduling

• Budgeting / P&L • Safety Awareness • Empowerment / Accountability

• Procedures & Policies • Cost Control • Automation

PROFESSIONAL EXPERIENCE:

American Trim • Sidney, OH 2009 – Present

PRODUCTION MANAGER 2012 – Present

Manufacturer supplying decorative parts for Whirlpool appliances, GM, Honda, Chrysler, and heavy truck

• Manages 120 direct reports and 35 indirect employees in decorative parts division comprising screen

printing, assembly, production, and stamping up to 600 ton presses producing aluminum control panels

• Realized 25% increased efficiency in press room that cut changeover time 60% as result of Kaizen event

• Increased production throughput by improving workflow, resulting in $200K per year savings on labor costs

Championed project of organizing teams and moving production lines from KY to OH due to company acquisition by implementing best practices to meet customer demands, resulting in 20% earnings margin

• Reduced changeover time 50% in screen print, realizing 20% efficiency increase from Kaizen process

• Implemented line balancing event for production line efficiency raising throughput 33%, saving $150K/yr

• Decreased turnover using employee empowerment, retention, and development strategies

Introduced purchasing idea for reducing material gauge thickness resulting in $300K savings

• Cut downtime 20% by organizing team to troubleshoot and redesign robotic tooling fingers in-house

• Started safety awareness training by engaging employees in conversation and coaching on safe concepts

QUALITY ENGINEER 2009 – 2012

• Streamlined manufacturing systems in decorative parts division working with APQP team on continuous

improvements to enhance safety, quality and productivity

• Reduced scrap from 2% to under 1% by applying Stop at Defect, First Piece, and Right the First Time methods

Lowered reworks by 45%, and diminished bad parts from 50 to 10 by implementing stop at defect controls

• Developed APQP team to improve downtime and reduce scrap in screen print during TS system execution

• Lowered VOC permit limit by teaming with supplier to develop clean-up solvent that improved emissions

Faurecia Exhaust Systems • Troy, OH 2004 – 2009

PROCESS ENGINEER 2007 – 2009

Tier 1 automotive manufacturer of exhaust worldwide for Jeep, Dodge, Chrysler, and converters for GM

• Supported customer PPAP’s, PFMEA, process flow, standardized work, and run at rate documentation

• Met with manufacturing to review scrap, production rates, and quality issues; applied corrective actions

• Managed project for gate reviews to ensure budget constraints and time deadlines were attained

• Held weekly meetings with all departments to communicate upcoming engineering change notifications

• Analyzed line and plant QRQC’s, and initiated countermeasures to correct issues; purchased equipment

QUALITY ENGINEER 2004 – 2007

• Administered PFMEA’s, Control Plans, and PPAP’s, aiding in the ramp up and launch of new programs

• Worked with design group on manifolds, hot ends, and cold ends parts design for manufacturing capacity

• Assisted Process Engineers during equipment run offs, and in set up and process flow of lines running parts

• Purchased all gauges and leak test equipment; led quality team in documentation for tracking internal issues

MANUFACTURING ENGINEER – Calsonic Kansei • Shelbyville, TN 2002 – 2004

Tier 1 exhaust manufacturer supplying Nissan that applies Lean Manufacturing and Kaizen principles

• Performed tool design, gauges, fixtures, and machine layouts; used AutoCAD and Mechanical Desktop

• Led manifold line, and supported PPAP, process sheets, PFMEA, ECN responses for constant improvements

• Assisted production lines with program updates for process improvement and quality assurance

• Oversaw plant-wide installation and assisted in setup, training, and completion of proper documentation

• Determined machine purchases based on specs, capabilities, cost and approved first run before shipment

PROJECT ENGINEER - CM Products • Manchester, TN 1999 – 2002

Automotive Tier II supplier of formed wire (.003” to ”) components including hood rods and seating wire

• Oversaw programming, maintenance, and process improvements on Motoman robotic weld cell

• Headed new job start-ups, designed fixtures for quick program changes, and ensured quality welds

• Performed design and upkeep of tooling, jigs, fixtures, and gauges using AutoCAD

• Improved cam driven process tool design and worked with wire form specialty machines and press dies

• Quoted tooling for custom parts involving forecasting, calculations, and communication with toolmaker

CERTIFICATIONS / TRAINING & DEVELOPMENT:

MRC / XRC Basic Arc Weld Robotic Programming training certificate – Motoman

PFMEA training – American Trim and Daimler Chrysler

360 Reviews • Situational Leadership – American Trim

PPAP, APQP Powerway training – Daimler Chrysler

EQUIPMENT: Motorman robotics • Allen Bradley PLC controls, Smartpac (interface between tooling

and equipment sensors) • Presses and Press dies • Auto welders (Melton)

MATERIALS: Aluminum • Low-grade Stainless Steel • Grade A Stainless • Carbon steel (.003” to ” wire)

COMPUTER / TECHNOLOGY: Word, Excel, Project, PowerPoint, AutoCAD (design), EDI / ERP

(Routing, BOM, Material Forecasting, Ordering, Scheduling)

EDUCATION: Bachelors Degree in Mechanical Engineering - University of Tennessee at Chattanooga

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