**Kenneth P. Mallasch

*** ***** *** ****** ***** KY. 42171

Phone: 270-***-****

Email Address: ad0bpn@r.postjobfree.com

Summary

Significant experience as a Tooling Engineer (starting as Tool Maker) working with Progressive Dies, Transfer Dies, Fine Blanking Dies, Deep Draw Dies, Forming Dies, Line Dies & Single Stage Dies, high speed stamping, sliding die transfer dies, fine blanking dies, progressive fine blanking dies, eyelet machines, four slide machines, multi slide machines, roll forming, laser cutting, and turret punching machines.

Solid expertise in tooling and production systems in metal forming.

Many years’ experience in design, tooling builds, purchasing, quoting, quality control, new product launches, and overall lean manufacturing and operations.

Developed PPAP’s, FMEA’s, Corrective Actions, Continuous Improvement’s, and specific value engineering exercises.

Proficient in metal forming simulation and design utilizing Unigraphics nx7.7 and Catia v5.

Professional Experience

Sierra Space Denver Tooling Manager March 2022 Present

Set up toolroom for Sierra Space Dream Chaser space plane

Toyota San Antonio Texas

Class A Tool Engineer Contract Tryout Process Engineer March 2021 March 2022

Bowling Green Metal Forming - Bowling Green, KY March 2017 –March2021 Tooling Engineer

Working for one of the world's premier global automotive suppliers providing a comprehensive range of body, chassis and engineering solutions to OEM customers.

Responsible for all tooling, deep draw, and progressive dies

Responsible for tooling of the Ford Escape engine cradle - 15 dies, $4.5 million in tooling, progressive and transfer tooling.

Responsible for tooling of the FCA WS SUV frame - 130 parts. $40 million in tooling.

Currently engaged in a Stamping Optimization project, with an estimated 2.5 mil savings, due to increased efficiencies.

Husqvarna - McRae, GA March 2014 – 2017

Tool Engineering Mananger

Working as the Tooling Manager for major manufacturer of outdoor power equipment. This plant made parts for the lawn mower business. The plant closed when Husqvarna left the push mower business.

Responsible for all tooling in 2 Plants deep draw, and progressive dies

Responsible for 2 tool rooms, with a total of 25 – 30 toolmakers

Responsible for all existing and new stamping dies, die maintenance, die installation, and first article trials.

Selected and worked with outside vendors on die construction.

Moved presses from plant 2 to plant one, set up presses, and automated all presses with new robotics.

Boeing – Charleston, SC July 2012 – 2014

Contract YOH Tooling Engineer

Working in the Boeing in the aft body fabrication department. Responsible for ship side support in composite fabrication layup post cure in their clean room. I also support the machining of aft body section 47 and 48 NDI testing, as well as the drilling and assembly of ribs, stringers, and flooring on segment 47 & 48. I also supported joining operations and the use of CATIA to design fixtures and tooling.

Was responsible for a second set of tools built to offload the PCS product line to an outside vendor.

Reviewed and updated 8 different layup tools that produced 86 different carbon fiber 4 ply shims used as sacrificial material in fitting different parts of airframes.

Designed expanded metal platforms for section 47 and section 48 carbon fiber layup tools. Using Catia Velocity

Designed a platform for working on station 90 where section 48 and section 49 carbon fiber tools are bagged and covered for the autoclave.

M.S.I. July 2011 – July 2012

Contract Tool Engineer

Worked in China for one year as a Contract Tool Engineer utilizing CATIA to design tooling.

Worked with needed tooling for New Nissan electric car roof to support center pillars, front pillars, and bumper brackets.

Designed and built a coil fed 6 station transfer die. Material was 1.6mm sp782BQ reinforced for the Dash upper front door hinge.

Designed and built a coil fed 5 station transfer die. Material was .65mm sp781BQ Ext Cowl Top

Designed and built dies for a 7-station progressive die. Material sp781BQ .65 thick

Designed and built 10 small progressive dies from 5 to 10 stations that were run in 200-ton press. Thickness varied from .8mm to 1.4mm thick - all 1010 plain carbon steel.

Designed and built 10 medium sized progressive dies from 8 to 15 stations that were run in 400-ton press thickness varied from .8mm to 1.4mm thick all 1010 plain carbon and high strength low alloy steel.

Delivered production samples on time for vehicle launch, following a step-by-step process for tool follow up –

strip layout - 50% complete design - 100% complete design - Detail - Material ordered - Rough machining - Heat treat final machining - Assembly trial 1 spotting - trial 2 - trial 3 good parts capability studies and run at rate - check the die by completely dissembling the tool and check all details.

During this time, I developed a new forming process. In plain carbon steel, this part would be formed in one stretch form operation for ultra-high strength steel. We had to add a draw operation and then a form and 2 cam trims in order to make parts without cracks.

Aerotech July 2010 - July 2011

Contract Tool Engineer

I was a Contract Tool Engineer at Carrier Corp a world leader in HVAC, Refrigeration, Fire & Security solutions.

Contracted to set up manufacturing process for new high efficiency furnace.

Installed a new $8,000,000 press line in the Indianapolis Plant that would form and assemble drawn heat exchangers using aluminized steel and stainless-steel run in the same die.

oThe first part of press line consisted of an 800-ton Minster press with a 240” bed with a 3 axis Wayne trails transfer system the die was a 6 station draw restrike and trim die which would run aluminized steel or stainless steel in the same process.

oThe transfer system would then drop off the part on a transfer conveyor which would transfer the parts to a washer it would rotate the part 90 degrees into the wash station then rotate the part back 90 degrees coming out of the wash station.

oThe conveyer would then split the production into 2 identical 600-ton minster press lines, these had 10 axis transfer systems. 1st station would part the haves then the transfer would rotate the half 180 degrees. The edges would then be crimped together in the next 2 stations and torn locked together.

oA finished heat exchanger would come off the end of the press and loaded onto a conveyer which would bring it to the new high efficiency furnace assembly line.

Production started on time and within budget.

Heath Craft 2008 – July 2010

Tool Maker

Worked as a tool maker during the downturn in the economy.

Temporary position while looking for a position in tooling engineering or management.

Bowling Green Metal forming a Magna Company 2004 – 2008

Tooling Engineer / Tool Die Supervisor

Working for one of the world's premier global automotive suppliers providing a comprehensive range of body, chassis and engineering solutions to OEM customers.

Worked on Ford 250, 350, 450, and 550 truck frames. In total, I worked with 19 different styles of frames with 88-part numbers, a total of $20,000,000 in tooling, running in presses up to 4,000 tons.

Designed die tooling for a new edge bend forming process for the F-250 truck frame. This was run in line, in a 2,000-ton press, and in a 2,000 ton,4,000-ton, 4,000 ton,2,000-ton Schuler tandem press line. A 12” x 240” x.312” blank was held with nitrogen cylinders while cams offset the 12” blank 3”. We had to utilize auxiliary hydraulic cam returns that were timed with the press. This was the first time this was done, in line, in a press operation.

Designed and built a 4-station transfer die for the #1 cross member that ran in a 2,000-ton Schuler press. Previously this was done in an 8-station transfer utilizing several presses. We eliminated several stations by making an aerial cam die with 6 aerial cams.

Designed and built 2 sets of 4 station transfer tools, with 6 changeovers, to produce 6 sets of

Crew cab rear rails, that were run in a Schuler tandem press line.

Designed and built 2 sets of 4 station transfer tools, with 14 changeovers, to produce 14 sets of

Chassis cab rear rails, that were run in a Schuler tandem press line.

Designed and built 1 set of of lh and rh inner front rails, and lh and rh outer front rails, with 1 changeover for the outer front rails that would change the material from 7mm to 8mm and were run in a Schuler tandem press line.

Designed and built 15 different cross member 4 to 6 station transfer dies that ran in an 800 ton or 1,000-ton transfer presses. Material was high strength low alloy from 3mm to 6mm thick.

Designed and built 10 station progressive die for gussets.

Designed and built 4 sets of transfer dies for spring brackets that ran in a 1,000-ton progressive/ transfer press.

Designed and built 4 sets of mounting bracket dies that ran in an 800-ton progressive/transfer press

Designed 1 set of lh and one set of rh angle reinforcements dies, with 10 changeovers, that ran in the Schuler tandem press line.

Involved in building a factory for ford F250 truck frame and ford Explorer frame.

oStarted up a 1,000,000 Sq Ft new manufacturing facility.

oProduction started on time and within budget.

Set up standards and implemented a Quick Die Change System.

oWe removed the dies from the end of the presses, one side had the die staged ready to run

oThe system would auto unclamp the dies, raise the ram and automatically move the dies to the idle station on one side of the press, and then move the dies in position from the other side of the press

oUsed on 2,000-ton Tandem line and 2,000-ton Transfer press.

oThis included writing over 3,000 pages of changeover instructions for the rear rail tooling.

Developed alternate forming tools, eliminating the need for heat treat polishing and coating, reducing tooling cost and lead time.

Steel Parts Corporation - Tipton, IN 2000 – 2004

Tooling Engineer

At this production facility we utilized 29 presses, ranging from 5 tons to 800 tons. Services included fine blanking, metal finishing, de-burring, roll flattening, heat setting and machining.

The company had not received any new work for the previous 2 years I worked there and needed to bring in new work to increase sales. Changed the estimating process by concentrating on assemblies and packaging of parts from customers. Focused sales on utilizing existing equipment that was sitting idle.

Brought in more than $10 million in new business my second year.

Developed new two body mount parts. One was a 14-station progressive draw die with multiple draws and reverse redraws. The other was a 12-station transfer die within line tapping for the Ford F150 truck with 4,000,000 pieces a year.

Developed robotic weld systems for welded stamped control arms that were made of high strength low alloy steel. Designed and built four 6 station, 2 axis transfer dies with indie transfer system for the same control arms.

Principal Manufacturing Corporation - Broadview, IL, 1999 – 2000

Tool & Die Engineer

Responsible for the design of progressive dies, fine blank dies, and draw dies.

Hired to shorten design times and build times for new tooling

Upgraded designs from 2D to 3D utilizing CATIA and standardized tooling, die sizes, shut heights, and pass lines.

Made a standard library of components in CAD to use during the design process.

Harley Davidson - Kansas City, MO 1996 – 1999

Tooling Mananger

Move Sportster bike production from York, PA to Kansas City. This consisted of two single station deep draw dies for the gas tank a single station deep draw die for the fender. Rather than use the hard tooling for the trimming and piercing of these I developed a 5 axis fiber optic YAG laser system that was placed next to the press utilizing scribe lines to program with the ability to manually edit size and location of holes and trim. This same system was able to support the new V Rod motorbike we were developing for the plant.

Specified production equipment for the manufacturing of class AA. Styled surfaces and equipment layout of stamping facility. Designed and built all tooling installed for production stamping equipment. Hired and trained press operators and tool and die makers.

Met all budget and timing goals for start of production in January 1998. Full productions started June 1998. Three months after new model launch in July, Harley received ISO certification.

Helped develop HPWO in plant, where a 60-man fabrication department is working with no supervisors as a self-directed work group. I was a coach and mentor for the tank and fender Natural Work Group.

Developed new hi-tech v rod motorcycle utilizing aluminum for fenders, gas tank, and radiator which could be brushed aluminum with clear coat or anodized for different colors

oFor the gas tank, I developed a deep draw process for Aluminum and a new trim & pierce process (shimmy trim die)

oOn the fender I developed a stretch form and a draw die for aluminum.

oThe radiator retainer was a 6-station progressive draw die for aluminum.

Developed laser trimming and piercing processes for the aluminum gas tank and fender to shorten engineering change time from several months to several days. We utilized a 5-axis fiber optic YAG laser that was placed next to the press, utilizing scribe lines to program, with the ability to manually edit size and location of holes and trims

Central Manufacturing - Parker City, Indiana 1988 – 1996

Engineering Manager/ Tool Die Mananger

Responsible for hiring, training, supervising, and evaluating up to 15 tool and die makers in all facets of building and repairing tools in addition to process improvements. Also responsible for sales and customer service.

Served as liaison with clients and dealt directly with buyers.

Awarded tooling jobs, selecting outside tooling vendors that ensured quality.

Worked under deadlines and following all aspects of project management.

Before I started with the company, they had lost about 4 million of 7 million in sales from a major customer, due to poor quality and late deliveries. I was responsible for getting that customer back and bring on new customers.

Increased sales from $3 million a year to $15 million.

Concentrated on die maintenance to run good parts on time, all the time. Started tracking down time, rework cost, and scrap cost to identify the top 10 problem tools. Corrected or changed tools to produce good parts.

Worked on a quick die change to reduce setup cost and be able to do shorted runs.

Developed a 10 station, deep draw progressive die, for the motor mount of the Ford Taurus SHO car that was made of high strength low alloy steel.

Developed a 7 station 3 axis, HMS transfer die, for a motor mount in the Ford minivan that was made of high strength low allow steel.

Developed four new robotic weld systems for welding muffler hangers and motor mounts. Used a Motorman 1000 standard weld cell, with quick change tooling plates. We only had to tool up weld fixtures for new parts

Developed a new Hybrid progressive / transfer / mandrel form die for a high strength wrap around motor mount eliminating several secondary operations.

Responsible for project management of 10-40 new parts a year.

Involved in the building of a new 35,000 sq. foot manufacturing facility.

Assisted in negotiations of new tooling programs with three new overseas customers.

Developed overseas tooling sources.

Eveready Battery - Cleveland, Ohio 1981 – 1988

Computerized Die Design Specialist

Responsible for managing all aspects of a three-man computer aided design department that designed progressive and transfer dies. I designed new tooling, placing it with outside vendors. I also made process improvements and performed other duties as required.

Responsible for reducing cost and shorting lead times for short runs - less than 500,000 prototype battery cell cases and seals.

Developed new sliding die transfer press process which reduced tooling cost by 50%. This process utilized a lower die shoe that would move 3” left on one stroke of the press, and then 3 “back on the next stroke of the press. The parts were held in the tool by vacuum for each 2 strokes of the press. The advantage of this process was that you did not have any transfer fingers and could more accurately form the part. We were constantly holding tolerances of .0001 to .0005.

Decreased design time from three weeks to three days by implementing CAD designs of new tooling and standardizing tool designs.

Developed stamping process for bi-clad and tri-clad materials including copper, stainless steel, nickel, and stainless-nickel.

oWrote a program that would calculate the required draw reductions to correctly form parts.

oWe were also able to calculate the blank size required to correctly form a part. We were required to hole reverse redraw flange heights, plus or minus .0005, to ensure correct battery sealing on new lithium coin cells.

Educational Background

Journeyman Tool & Die Maker @ Modern Tool & Die Cleveland, OH / Completed Ohio State Apprenticeship

Cuyahoga Community College @ Cleveland, Ohio / 2 years in Manufacturing Engineering

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