Cris Salazar, Jr.

Fremont, CA Cell: 858-***-****

E-mail: acxkts@r.postjobfree.com

PROFESSIONAL SUMMARY

•Experienced manufacturing, process, sustaining, quality, industrial, test, and field service engineer; quality and production supervisor, production trainer, technical content writer, project coordinator, facility space and event planner.

•Detail-oriented, problem-solving manufacturing professional who rolls up his sleeves in order to understand and investigate production issues, or improve existing production process.

•Supported daily production activities for companies within: automotive, aviation, consumer electronics, gaming, health care, marine, medical device, military and defense, semi-conductor, and telecommunication industries.

•Work experience includes: new product introductions (NPI); development of production/assembly lines; fixing production and process problems; writing standard operating procedures (SOPs); performing time/motion studies; ensuring process & quality adherence by providing proper tools, fixtures, equipment, methods; optimizing processes; applying cost reductions.

•Hands-on experience in: printed wiring board assembly (PCBA); electro-mechanical assembly; wiring harness & cable assembly; gear and transmission assembly; seating & upholstery assembly; electric motor and battery pack assembly; integration testing of hardware and software; non-conformance material dispositions (NCM/MRB); configuration control & change management.

•Work skills include: supporting contract manufacturers (CM); driving corrective actions to improve 1st-pass-yields; defect data analysis; writing request for quote (RFQ/SOW) specifications, project management; and root cause corrective actions (RCCA).

AREAS OF EXPERTISE

•Process Optimization

•Make vs. Buy & R.O.I. Analysis

•Project Management incl. Capital Equipment

•Space Planner & Floor Layouts

•New Product Introductions (NPI)

•Apply 8D, 5S, DMAIC, Kaizen, Lean Principles

•Technical Writer (SOPs) & Trainer

•Defect/First-Pass-Yield Data Analysis

•Contract Manufacturers (CMs) Support

•Time-Motion & Ergonomic Studies

•Scope of Work & RFQ writer

•Electro-Mechanical Assembly Processes

PROFESSIONAL EXPERIENCE

Industrial Manufacturing Process Engineer – Volunteering at Non-Profit/Charities (San Francisco Bay Area) (2015 – 2016)

Working at non-profit and charitable organizations by providing hands-on engineering assistance in support of daily activities.

KEY ACCOMPLISHMENTS:

•Perform time-motion analysis on food preparation and distribution tasks performed by volunteers and paid staff.

•Introduce lean manufacturing techniques of 5S & visual workplace to facilitate work and improve communications.

•Identify bottlenecks in food movement and staging; redesigning areas for more effective space utilization.

•Identify tasks with potentially risky ergonomic motions; implementing solutions by redesigning work spaces.

•Recommend alternate methods & equipment to facilitate distribution of food to 200-300 needy families per week.

Industrial Manufacturing Sustaining Engineer – Tesla Motors (Electric automobile manufacturer) (2010 – 2014)

Hands-on experience in various roles supporting daily production processes related to: battery pack, electric motor, transmission, sunroof, windshield/glass installation, seating and door panels. Project managed refurbishment of half-mile-long, 20-year-old conveyor system used to transport tire and wheel assemblies to production line point of use. Wrote request for quote (RFQ)/scope of work (SOW), then project managed design and implementation of capital equipment ($15M) used to assemble and install panoramic roof, windshield and rear window to support factory goal of a 500% increase in vehicle production.

KEY ACCOMPLISHMENTS:

•Coordinated transfer of electric motor (Taiwan) and transmission assembly (U.S. supplier) from contract manufacturers to in-house operations: designed workstations; purchased equipment/tools; developed processes; wrote SOPs & trained workers.

•Designed production area layout to improve cycle time 30% for battery module assembly process.

•Created over 100 technical documents: manufacturing work instructions; rework/repair; test; material handling; ESD controls; material non-conformance; defect identification/quality acceptance, workmanship standards, and other SOPs.

•Received “Outstanding Achievement” award (Jan 2012) as sustaining engineer responsible for supporting production of Toyota RAV4 drive units (electric motor/transmission, battery packs) during critical new product introduction period.

•Completed numerous time-motion studies to determine cycle times, work sequences, throughput rates, and manpower requirements for assembly of battery pack, electric motor, transmission, panoramic roof, door panel, and 3rd row seat.

•Supervised 10 technicians, setting daily assignments, reviewing work related issues, and addressing any other administrative tasks related to their employment, including writing performance reviews.

•Designed non-conforming material areas: creating overall layout; procuring equipment (storage racks, shelves, workstations, ESD protective storage) and tools; defining repair and rework procedures, and general flow of materials in and out of area.

•Contributed to development of PFMEAs for all three powertrain components: battery modules; battery packs; electric motor.

•Spearheaded implementation of ESD controls, materials, processes, and handling methods throughout factory.

•Lead rework/recall project, involving Toyota RAV4 transmission field returns, to correct design issue located inside gearbox.

•Created failure analysis procedure, used on every drive unit (electric motor & transmission) failing NVH/dyno testing.

•Investigated noisy transmission gear issue; resolved by implementing an improved demagnetizing and gear cleaning process.

•Re-designed panoramic roof frame subassembly production area: creating custom assembly fixtures and procuring new semi-automated tools to support production ramp from 25 to 150 units per day, a 500% improvement.

•In less than 9 weeks, transformed prototype seat assembly area to production ready, capable of supporting daily schedule.

•Responsible for transferring door panel assembly in-house saving $200 per car: designed U-shaped conveyor assembly line; procured tools and equipment; created work instructions; trained personnel; worked with electricians, plumbers, I.T., and facility departments to prepare production area to support daily production rate.

Senior Manufacturing Process Engineer – Cobham Advanced Electronic Solutions (Military electronics manuf.) (2005 – 2010)

Supported production floor activities through investigation of daily production issues and implementation of corrective actions; numerous design, method, and documentation improvements were devised and implemented. Participated in Kaizen, 5S, lean manufacturing, and other continuous improvement events, resulting in process improvements at all levels of production. As process documentation release chairman, improved all standard operating procedures (SOPs) through incorporation of images, drawings, flowcharts, and easy to understand text for workforce with English as a second language. In 2009, received corporate “Commitment to Excellence” award, for idea on how to engage hourly employees (subject matter experts) more effectively.

KEY ACCOMPLISHMENTS:

•Investigated production floor issues, resolved through implementation of tools, process, or documentation changes.

•Reviewed first-pass-yield data, identifying root cause(s), implementing corrective actions.

•Over 500 engineering change orders (ECOs) written to correct design, BOM structure, and process documentation issues.

•Automated manual assembly processes to reduce both assembly time and labor cost (15% savings).

•Chairman of process documentation release team leading compliance to “Visual Workplace” company initiative.

•Material review board (MRB) and configuration control board (CCB) participant; dispositioned material & set configuration.

•Directly contributed to company’s Lean Manufacturing initiatives by: designing mistake-proofing (Poka-Yoke) fixtures & tooling; initiating 5S improvements; value stream mapping of current & future states (process steps); participating in Kaizen & process failure mode effects analysis (PFMEA) events; creating graphics-based process and training visual aids.

Manufacturing Process Sustaining Engineer – Denso Wireless Systems (Infotainment systems supplier) (2004 – 2005)

Provided daily equipment operational checks including analysis of SPC data. Supported 5S and lean manufacturing efforts by auditing various factory areas and identifying issues of non-conformance. Working with software engineers, improved functional test procedure by streamlining process which led to a 15% reduction in test times.

KEY ACCOMPLISHMENTS:

•Applied Lean Manufacturing strategies of 5S, Poka-Yoke, and Kaizen events to production areas and individual work stations.

•Optimized automated dispensing equipment to perform more efficiently, reducing cycle time and waste material by 20%.

•Developed standard operating procedures (SOPs) and tooling/fixtures for manufacturing & production assembly areas.

•Improved functional test cycle times 15%: minimizing unnecessary operator motions & deleting redundant test steps.

•Devised various solutions to difficult process operations in order to facilitate manufacture of product.

Test Field Service Engineer – Vectron, Inc (Automated optical inspection equipment manufacturer) (2000 – 2004)

Executed integration testing and evaluation plan on every completed unit prior to shipment of product. Performed numerous calibration steps on product prior to final acceptance/functional testing. Traveled to customer sites to unpack, setup, and verify product/machine performance before release to customer. Trained customer personnel on operation of unit, providing both classroom and hands-on training. Performed phone support, field upgrades, debugging assistance of equipment when warranted.

KEY ACCOMPLISHMENTS:

•Planned, coordinated, and executed integration testing & evaluation of multiple hardware and software platforms.

•Wrote detailed manufacturing and test procedures, operational standards, and quality assurance procedures.

•Traveled to customer sites performing support activities involving installation, training, and field upgrades or repairs.

•Contributed to new product releases by identifying any hardware or performance issues, and/or software bugs.

•Planned and coordinated trade show event participation by working with internal/external vendors to coordinate logistics.

Product Supplier Quality Engineer – Qualcomm, Inc. (Cell phone equipment manuf.) (1997 – 2000)

Maintained quality assurance standards across 4 surface mount technology (SMT) printed wiring board assembly (PCBA) production lines producing over 20,000 assemblies per month in high product mix factory. Analyzed daily defect data to determine trends. Held production review meeting, assigning corrective actions where warranted. Worked closely with design/hardware/test engineering to improve product’s design for manufacturability. Managed daily work assignments for 8 QA technicians.

KEY ACCOMPLISHMENTS:

•As quality engineer assumed leadership role raising first-pass-yields from 54% to 96.7% within a 5-month period.

•Qualified PCBA automated optical inspection (AOI) system, resulting in 30% gain in first-pass test yields.

•Implemented Poka-Yoke in-process test to verify product mechanical operation, improving functional test yields by 43%.

•As supplier quality engineer, developed material marking/packaging requirements, reducing supplier returns by 20%.

•As part of a cross-functional team, submitted various cost cutting methods resulting in a 28% packaging cost reduction.

•Contributed to the development and release of a corporate-wide quality/workmanship standards manual.

•Co-developed hands-on defect/quality training program that became corporate standard for all new hires.

NPI Manufacturing Process Engineer – Telco Systems (Telecommunication equipment manufacturer) (1995 – 1997)

Supported in-house assembly and contractor manufacturing activities by resolving process, material, equipment, and documentation issues. Focal point-of-contact for all new product introductions. Wrote corporate “Design for Manufacturability” guidelines for design engineers to follow. Devised new assembly methods which contributed to cost reductions in assembly times and improvement of first-pass-yields.

KEY ACCOMPLISHMENTS:

•Supported 20 contract manufacturers (CMs) resolving: design, material, process, ECO and other documentation issues.

•New product introductions manufacturing representative including assembly of prototype, pre-production & pilot builds.

•Material Review Board (MRB) chairman responsible for dispositioning non-conforming production materials.

•Optimized return material authorization (RMA) field failure repair process implementing changes which reduced time by 30%.

•Co-authored design for manufacturability and testability corporate guidelines.

Manufacturing Process Sustaining Engineer – Applied Materials (Semiconductor equipment manufacturer) (1994 – 1995)

Structured product bills of materials, released assembly drawings, and wrote engineering change orders (ECOs) to support “as-built” product configurations. Supported company’s ISO certification by writing numerous technical documents on assembly, test, and shipping processes. Implemented and integrated customer specified options on silicon wafer processing equipment.

KEY ACCOMPLISHMENTS:

•Responsible for driving corrective action and failure analysis of non-conforming sub-assemblies from outside suppliers, resulting in 50% increase in receiving inspection acceptance levels.

•Provided sustaining engineering functions such as: failure analysis, cost reductions, engineering change orders.

•Contributed to ISO 9001 certification: wrote comprehensive list of assembly, quality, shipping, and test documents.

•Defined and specified the implementation of standards, methods, and procedures for inspecting, testing, and evaluating the precision, accuracy, and reliability of company products.

Industrial Automation Process Engineer – Silicon Graphics, Inc. (Computer workstation manufacturer) (1992 – 1994)

As part of five-man engineering team, 200,000 square-foot building was gutted, then redesigned with automated systems to support assembly of computer workstations. At completion of project President Clinton and Vice-President Gore toured factory in February 1993. Responsible for design of conveyor system “smart pallet” which moved product throughout factory from assembly through burn-in, to shipping. Created Kanban and JIT (just in time) material delivery systems.

KEY ACCOMPLISHMENTS:

•Integrated automation equipment into multiple high-volume production areas, increasing overall throughput 50%.

•Project managed development and manufacture of 800 highly complex conveyor system pallet assemblies made up of castings, sheet metal, electronic components, and ESD safe materials.

•Reduced overall assembly times by 30% through methods and productivity improvements including: new process flows using Kanban & JIT, procurement, and utilization of new equipment and production processes.

•Designed ergonomic final pack out and shipping workstations which included pneumatic/hydraulic lift assists to aid lifting 40 lb. computer and 80 lb. CRT display.

•Project leader in redesign of key conveyor system component, saving over $200 per unit/$40,000 overall.

•Responsible for selection & purchase of over $2M in tools, equipment, materials to improve productivity throughout factory.

EDUCATION

•B.S., Industrial Technology, San Jose State University, San Jose CA

•A.S., Natural Science, Ohlone College, Fremont CA

TECHNICAL KNOWLEDGE

•Working knowledge of:

•IPC-610 - workmanship standard

•ISO 9001 - quality management

•IPC/EIA-J-STD-001 - soldering

•GMP/QSR - medical devices

•Bellcore - telecommunication standard

•Lean Manufacturing - methods and techniques.

•MS Office skills:

•Outlook

•Word

•Excel

•PowerPoint

•Project

•Sharepoint.

•Visio

•Windows and Mac OS computer software experience:

•Adobe Acrobat

•Arena PLM

•QuickBase

•Adobe Photoshop

•AutoCad

•SAP and other various ERP systems

•Adobe Photoshop Elements

•Catia 3D Live

•Warp Drive (document storage)

•Apriso (MES)

•Enovia PLM

•Tortoise SVN (document revision control).

•Exceptional technical writing/documentation, and verbal communication (bilingual in Spanish) skills.

•Strong project and capital equipment procurement leadership and management experience.

•Photographic skills include:

•Images captured with camera (DSLR)

•Edit images in Adobe Photoshop

•Create standard operating procedures with Microsoft Word, PowerPoint, Adobe Indesign or other application.

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