ALEX N. TURKAI

ad2tp1@r.postjobfree.com - 505-***-**** - Albuquerque, New Mexico

Manufacturing & Plant Logistics Engineer

Assembly Plant Logistic & Manufacturing Engineering Career

20+ years with an automotive fortune 100 company

Experience in research, benchmark and testing of new in-plant logistics technologies such as autonomous mobile robots and automated storage and retrieval systems

Experience working with cross functional teams in product development, finance, manufacturing engineering, ergonomic and industrial engineering

Experience in driving efficiency, optimizing material flow, packaging and part presentation in the assembly line

Experienced in designing and launching large in-plant logistic programs, financial forecasting, equipment purchasing, setting up large third-party logistics services centers

Experience in automotive parts shipping container concepting, forecasting and purchasing,

Experience in program launches, plant layout optimization, material handling equipment and automation specification, assembly workstation optimization, material sequencing and kitting requirements, third party logistics services contract management

Used a variety of tools and skills including: Lean Manufacturing FactoryCad FactoryFlow AutoCAD Catia VisMoc TeamCenter

PROFESSIONAL EXPERIENCE

Ingot Dive Metalworks LLC Oct. 2022-Present

Business Owner

Started own company.

Provide unique one-of-a-kind Metal Art Works for outdoors art, furniture, gates, fences, decorations. 100% custom metal works to order

Create Model Design in CAD using AutoCAD and Fusion 360

Create CNC profiles using CAD/CAM software Autodesk Fusion 360

Manufacture, build and install products using CNC Plasma cutting and welding.

Sandia National Laboratories Nov. 2021-Sept. 2022

Senior Manufacturing Engineer

Albuquerque, New Mexico, United States

Design and implement End to End Logistics plan to support Assembly of Advanced one-of-a-kind High-Tech System.

Create & Implement: working Bill of Materials, Plan for Every Part, Material Flow Design, Receiving & Inspection process, Inventory warehousing plan and solutions, outbound packaging design, critical lifts, Material Handling equipment requirements

Prepare facility for Assembly: Assess Facilities readiness and Risk to Assembly. Assess floor and grating loading, power requirements, Lifting equipment.

Generate, own and manage Assembly Layout in 2D (AutoCAD) and 3D (CREO). Lead Layout development team, engage Product Development team, lead assembly process review and update layout with changes. Create point-in- time layouts based on what is being assembled, procurement and Program schedule changes. Generate Product Structure diagrams from PLM (CREO) software and create assembly flow charts. Drive make/buy decisions, increase in assembly efficiency and assess risks to create consensus on assembly process and assembly layout.

Support Assembly Documentation. Provide leadership on how-to and step-by-step assembly documentation. * Design and implement End to End Logistics plan to support Assembly of Advanced one-of-a-kind High-Tech System.

* Create & Implement: working Bill of Materials, Plan for Every Part, Material Flow Design, Receiving & Inspection process, Inventory warehousing plan and solutions, outbound packaging design, critical lifts, Material Handling equipment requirements * Prepare facility for Assembly: Assess Facilities readiness and Risk to Assembly. Assess floor and grating loading, power requirements, Lifting equipment. * Generate, own and manage Assembly Layout in 2D (AutoCAD) and 3D (CREO). Lead Layout development team, engage Product Development team, lead assembly process review and update layout with changes. Create point-in-time layouts based on what is being assembled, procurement and Program schedule changes. Generate Product Structure diagrams from PLM (CREO) software and create assembly flow charts. Drive make/buy decisions, increase in assembly efficiency and assess risks to create consensus on assembly process and assembly layout. * Support Assembly Documentation. Provide leadership on how-to and step-by-step assembly documentation.

Skills: Team Leadership · Cross-functional Team Leadership · Cross-functional Coordination · Risk Assessment · Material Flow Engineering · PFEP · PTC Creo · AutoCAD · BOM management · PLM Tools · Layout Design · WAREHOUSING · Packaging Engineering · Oracle Primavera

Ford Motor Company 2018-Sept. 2021

Process Innovation Manufacturing Engineer

Dearborn, Michigan

Create internal logistic concepts for factory of the future. Guide small agile team of Engineering resources to create 3D design of concept, 3D walk-thru experience, high level equipment breakdown and cost ranges. Use simulation tool to iterate designs and improve concepts as well as generate equipment requirement. Create business case for today vs. tomorrow processes of internal logistics.

Introduce concepts of Autonomous Mobile Robotic material handling and automated vertical storage solutions to automotive manufacturing internal logistics. Research, benchmark and recommend AMRs (Autonomous Mobile Robots). Acquire, review, test and pilot AMRs in laboratory. Implement piloted AMRs in beta test site. Drive business case and first introduction of AMRs to production floor. Lead review and approval of AMR with safety and labor relations as new technology. Coordinate with IT first-time installation of AMR fleet Manager and networking, communication and security requirements. Educate Manufacturing team on new technologies.

Key Accomplishments & Contributions:

Created first corporate benchmark study of AMRs and its supply base

Identified and sourced a project to partner in AMR and ASRS (Automatic Storage and Retrieval System)

Lead first AMRs (multi) installation in actual production, from ideation to launch.

Tested multiple vendor and form factor AMRs in lab environment

Created the first comprehensive vision for internal logistics of future with First-to-Market concepts

Guided Engineering resources to creating detailed solutions from Vision

Used Engineering resources to create multiple simulation scenarios to narrow down design and provide management with options

Ford Motor Company 2013-2018

Future Model Studies Shipping Container Engineer

Dearborn, Michigan

Simultaneously manage multiple large-scale future program studies. Breakdown bill of material. Create packaging design concepts for every part from hardware to large assemblies. Build Catia 3D virtual unique container for unique new large and medium parts. Maximize density of parts per container to reduce investment and freight. Design containers within constraint from finance, ergonomics, part presentation, part sequencing, shipping method, and workstation point of use space. Review and update container design based on feedback from end users. Generate container fleet size and cost by container. Provide program overall budget for shipping containers and update it at every program milestone as well as CAD maturity levels with Team Center PLM. Publish design concepts in Team Center and maintain/update revisions.

Handoff budget and designs to launch teams.

Key Accomplishments & Contributions:

Successfully completed container concept design, budget and handoff for a very large truck program at all of it milestones with a budget exceeding $100 mils

Completed container concept design budgeting and handoff of multiple truck, car and SUV programs

Created a new fleet calculation and budgeting tool for truck frames

Created, reviewed a completed how-to manual for future model studies of container concept design & budgeting. Trained other Engineers.

Ford Motor Company 2009-2013

Shipping Container Launch Engineer

Dearborn, Michigan

Simultaneously manage multiple large-scale future programs launches. Take containers from handed off concepts to production ready. Issue design orders and work with design houses to complete iterative design process with input from parts suppliers and internal customers. Issue orders for tooling, and fleet orders. Conducts reviews with part suppliers and internal customers for prototype container and first production article. Track order and financial status.

Ford Motor Company 2007-2009

Corporate Logistics services Contract Manager

Dearborn, Michigan

Establish scope of work and bill of materials for material sequencing and metering services by external logistics providers. Identify logistic services vendors as candidates for bidding on contracts. Solicit and obtain bids for services. Analyze bids. Negotiate all element of bids. Advise purchasing on sourcing decision. Issue purchase orders. Establish launch timeline & readiness. Review, re-quote and issue orders for scope of work changes during length of contract.

Generate rolling corporate wide financial forecast based on current and upcoming needs, by program and by plant. Review required funding with finance and secure funding. Identify, review and execute cost opportunity to reduce budgeted costs.

Key Accomplishments & Contributions:

Successfully managed contracts for 28 3rd party logistics provider sites. Created new rolling forecast tool and successfully submitted and secured funding of an average of $100 mils per year. Consolidated multiple vendor sites and contracts into single larger site at several plants. Significantly reduced number of providers. Continuously negotiated quotes and reduce cost per contract. Reduced overall contract obligation costs from $120 mils/year to $85 mils/year.

Ford Motor Company 1997-2007

Manufacturing Material Flow Engineer

Dearborn, Michigan

Simultaneously manage multiple future programs. Forecast requirements for material handling building, power equipment, ergonomic equipment, line side equipment, material storage equipment as well as material receiving and transport equipment. Work with IEs and Ergonomics to design optimum workstation line side material presentation. Generate requirements for inbound material sequencing metering and kitting. Create business case of inhouse vs. third party logistic services. Create master scope of work for material logistic services center. Secure program funding and work with purchasing for tier-one vendor sequencing service. Use AutoCAD, FactoryCAD to generate an maintain material flow layout. Use FactoryFlow software to help IEs generate indirect labor requirements. Work with process engineering on part allocation to assembly stations in order to optimize material flow density and reduce traffic congestion. Create labor saving opportunities with lineside automation. Quote and order all equipment forecasted. Assist assembly plant with launching new equipment and processes

Livernois Engineering 1995-1997

Application Sales Engineer

Dearborn, Michigan

Traveled to customer bases in Europe and Canada. Presented company products and worked with customers to solve their problems. Applications were in special machinery and tooling to fabricate parts for automotive heat exchangers.

GAN Engineering 1993-1994

Manufacturing Engineer

Tunisia North Africa

Set up an international working partnership between a company is Tunisia (GAN) and Chief Industries in Nebraska to design, manufacture and distribute turnkey grain elevator projects in North Africa

LANGUAGES

In addition to English, I am fluent in French and familiar with some Arabic Dialects.

EDUCATION

Michigan State University.

Master of Science, 1992

Material Science and Engineering

Michigan State University.

Bachelor of Science, 1990

Material Science and Engineering

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