JOSHUAKOOLS

Summerville, SC ***** 828-***-**** ad3gi5@r.postjobfree.com

Professional Summary

I'm going on 25 years in the High Pressure Die Cast Industry. I started as a Machine Operator and quickly grew into the role of a Set Up/Process Technician, then Process Engineer, with Production and Manufacturing leadership abilities. Able to develop new, sustainable and efficient processes. Proven to position organizations to evolve successfully.

Specialties: Aluminum Powertrain products along with Aluminum and Magnesium structural components. Experienced in product launch with over 50 new or take-over components, ranging from small recreational vehicle clutch and power train parts, to automotive castings, including

shock towers, crank cases, transmission cases, and cross car beams(Magnesium) and DCM sizes ranging from 400 Ton to 4400 Ton. Automation training and hands on experience with ABB and Fanuc robots. I strive to make problems go away and never come back. Permanent, long-term solutions. I put a ton of pride in my work as if every part has my name on it.

Skills

Process Flow Analysis

Relationship Building

Project Oversight

Documents and Reports

Training and Development

Lean Principles

Quality Assurance

Process Improvement Solutions

LeanManufacturing Concepts

Self-Motivated

Attention to Detail

Dependable and Responsible

Flexible and Adaptable

Analytical and Critical Thinking

Process Flow Analysis

Excellent Communication

Cultural Awareness

Problem-Solving

Process Development and Optimization

Cost Reduction

Six Sigma

Root Cause Analysis

Production Understanding

Schematics Understanding

Blueprint Understanding

Product Development

Detail Orientated and Results Driven

Great Work Ethic

Create Positive Atmosphere

Mindfulness

Work History

Process Engineer 06/2021 to 06/2022

Bocar US – Huntsville, Alabama

Reported on daily efficiencies, utilizations, shop supplies usage and productivity Worked off shifts to train new employees for a Mg product launch Collected and analyzed data for continuous improvement Daily review and monitoring of all process parameters vs documented process setpoints to assure consistent andrepeatable production of quality castings

Monitored daily production, quality requirements and quantity targets for all new and existing jobs Responsible for continuous cost reduction and improvements Improved any restrictions to the flow of production Daily focus on reducing scrap and improving productivity Involved in facilitating the installation of our fully automated die cast machine cells Worked with and trained other Process Optimizers, increasing yield by reducing variation, reducing cycle times, andoverall increasing in machine up-time and efficiency Implemented ideas for designing of gate and runner systems and recommended changes to reduce variation in thedie cast process

Have worked with dimensional changes to tooling resulting from CMM versus blueprints requirements Responsible for developing, implementing, and modifying processes on some of the tightest quality standardsknown in the die casting industry

Involved in working on PPAPs, APQP, FMEA and experienced with TS/ISO Also involved in feasibility studies to the die casting capability from drafts, cores, and wall stock thickness per theblueprint requirements

Involved in gating and runner designs, gate placement, along with venting designs Worked in melt rate usage versus the capacity of production requirements in product that is required to fillcustomer's requirements

Listened to machine operation to detect malfunctions Set up dies and accessory equipment

Observed continuous operation of machines.

Process Optimizer 06/2019 to 06/2021

GF LINAMAR – Mills River, North Carolina

Reported on daily efficiencies, utilizations, shop supplies usage and productivity Worked off shifts to train new employees for a Mg product launch Collected and analyzed data for continuous improvement Daily review and monitoring of all process parameters vs documented process setpoints to assureconsistent and repeatable production of quality castings

Monitored daily production, quality requirements and quantity targets for all new and existing jobs Responsible for continuous cost reduction and improvements Improved any restrictions to the flow of production Daily focus on reducing scrap and improving productivity Involved in facilitating the installation of our fully automated die cast machine cells Worked with and trained other Process Optimizers, increasing yield and quantity variation, reducing cycle times,and overall increasing in machine up-time and efficiency Implemented ideas for designing of gate and runner systems and recommended changes to reduce variation in thedie cast process

Have worked with dimensional changes to tooling resulting from CMM versus blueprints requirements Responsible for developing, implementing, and modifying processes on some of the tightest quality standardsknown in the die casting industry

Involved in working on PPAPs, APQP, FMEA and experienced with TS/ISO Also involved in feasibility studies to the die casting capability from drafts, cores, and wall stock thickness per theblueprint requirements

Involved in gating and runner designs, gate placement, along with venting designs Worked in melt rate usage versus the capacity of production requirements in product that's required to fillcustomer's requirements

Listened to machine operation to detect malfunctions Set up dies and accessory equipment

Observed continuous operation of machines.

Process Engineer 06/2017 to 06/2019

Empire Die Casting – Macedonia, Ohio

Documented all setup and programming procedures including work instructions on new machines andmaintaining existing part specific files

Reported on daily efficiencies, utilizations, shop supplies usage and productivity Collected and analyzed data for continuous improvement Daily review and monitoring of all process parameters vs documented process setpoints to assureconsistent and repeatable production of quality castings

Thermal imaging during process development and making necessary adjustments to help achieve optimalmold temperatures and thermal balance

Monitored daily production, quality requirements and quantity targets for all new and existing jobs Responsible for continuous cost reduction and improvements Improved any restrictions to the flow of production Daily focus on reducing scrap and improving productivity Involved in facilitating the installation of our fully automated die cast machine cells Worked with and trained other Process Optimizers, increasing yield by reducing variation, reducing cycle times, andoverall increasing in machine up-time and efficiency Implemented ideas for designing of gate and runner systems and recommended changes to reduce variation in thedie cast process

Have worked with dimensional changes to tooling resulting from CMM versus blueprints requirements Responsible for developing, implementing, and modifying processes on some of the tightest quality standardsknown in the die casting industry

Involved in working on PPAPs, APQP, FMEA and experienced with TS/ISO Also involved in feasibility studies to the die casting capability from drafts, cores, and wall stock thickness per theblueprint requirements

Involved in gating and runner designs, gate placement, along with venting designs Worked in melt rate usage versus the capacity of production requirements in product that is required to fillcustomer's requirements

Listened to machine operation to detect malfunctions Set up dies and accessory equipment

Observed continuous operation of machines.

Process Engineer 07/1996 to 06/2017

Team Industries Inc – Detroit Lakes, Minnesota

Documented all setup and programming procedures including work instructions on new machines andmaintaining existing part specific files

Reported on daily efficiencies, utilizations, shop supplies usage and productivity Collected and analyzed data for continuous improvement Daily review and monitoring of all process parameters vs documented process setpoints to assureconsistent and repeatable production of quality castings

Thermal imaging during process development and making necessary adjustments to help achieve optimalmold temperatures and thermal balance

Monitored daily production, quality requirements and quantity targets for all new and existing jobs Responsible for continuous cost reduction and improvements Improved any restrictions to the flow of production Daily focus on reducing scrap and improving productivity Involved in facilitating the installation of our fully automated die cast machine cells Worked with and trained other Process Optimizers, increasing yield by reducing variation, reducing cycle times, andoverall increasing in machine up-time and efficiency Implemented ideas for designing of gate and runner systems and recommended changes to reduce variation in thedie cast process

Have worked with dimensional changes to tooling resulting from CMM versus blueprints requirements Responsible for developing, implementing, and modifying processes on some of the tightest quality standardsknown in the die casting industry

Involved in working on PPAPs, APQP, FMEA and experienced with TS/ISO Also involved in feasibility studies to the die casting capability from drafts, cores, and wall stock thickness per theblueprint requirements

Involved in gating and runner designs, gate placement, along with venting designs Worked in melt rate usage versus the capacity of production requirements in product that is required to fillcustomer's requirements

Listened to machine operation to detect malfunctions Set up dies and accessory equipment

Observed continuous operation of machines.

Education

Ongoing : Business Management 04/2017

American InterContinental University - Atlanta, Georgia This is currently on pause. I'm in the process of changing schools, and will finish within a year. Certifications

AutoCAD Level 1

Die Cast Defects

Die Cast Machine Operation

Forklift

5S

Quality Assurance

Six Sigma

FMEA

PPAP

APQP

Microsoft Project

Coaching Skills

Effective Decision Making

Achieving YourHighest Priorities

7 Habits of Highly Effective People

Managing the Stress of Change

Accomplishments

- Participated in a significant project launch for Ford involving three fully automated 4400 ton magnesium cells.

- Developed the entire process by starting sampling with one die and one machine while the other cells were being installed and other dies were still being constructed.

- Implemented changes and modifications on all incoming items to ensure consistency in the end result.

- In the first run at rate for Ford, successfully ran all three machines producing identical castings, with the need to intentionally slow down production to conceal the real cycle time.

- Managed to complete a 12-hour run despite the overwhelming nature of working with magnesium for the first time, considering it as a valuable learning experience.

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