Michael D. Czapla

734-***-****

ad44uz@r.postjobfree.com

Seeking position as Continuous Improvement Engineer Summary of Qualifications

Bachelor’s Degree in Mechanical Engineering with 18+ years manufacturing engineering. 6 Sigma certified, Black Belt, Green Belt and Kaizen through Ford Motor Lean Academy Continuous Improvement Engineering: Develop and Execute strategies to achieve the best quality, costs, and lead times. Lead, manage, and document the validation and development of actions to introduce or revise products and processes. 15 years’ experience with tooling, machines, and process flow in machine shops. Writer of capital equipment expenditures, ERP/MRP routers. Quality Control Assurance: API, ATEX, CE standards for product quality, traceability, and certification. Expert in PC based tools (Word, Excel, and Power Point) and using SAP, ERP and MRP systems.

Work Experience

Quest Global – USA/México – Current –Process Consultant/Supplier Development Engineer

● Leading Kaizen events: evaluating business unit performance, re-establish metrics, train leaders in LEAN

● Teach Operations to improve safety, quality of process, product throughput, cost improvement, and process capacity.

● Supplier Development: establish and improve KPIs: OTD, PPM, and NPI/Change Control Oceaneering – Houston, TX 5/2020 - 6/2022 Process Engineer

● Improved ERP system for gathering Chain-of-Custody data: standardizing metrics for Utilization,

● Throughput, TPM, KPI and other supplier metrics, Oracle - PeopleSoft

● Corrected Labor Forecast resulting in savings of $600k- Reviewed and wrote Standard Operating Procedures for mobilizing off-shore equipment – ROV, BOPS. HPUs Draft annual budget for industrial engineering and continuous improvement goals Lamons Gasket – Houston, TX - 5/2017 - 3/2020 Senior Lean Engineer -Continuous Improvement

● Reduce Costs of Outside Process by Reducing Expediting Fees, more work done inside factory, more orders ran simultaneously to reduce trips, Statistical Analysis, improving manufacturing process efficiency.

● Achieved API 20E License, and ISO 9001 renewal: Prepared Supply Chain and Production Team for the

requirements, sustained the discipline for the License. Establish I 4.0 techniques for scheduling and inventory.

PlyGem Windows – Bryan TX- 5/2015 - 5/2017, Engineering Supervisor & Quality Manager

● Reduce In-Process Scrap – save $1.2MM in internal scrap with cross-reporting and accountability. Lead 3 process engineers and 8 associates in Quality Control, mentored in Lean Six Sigma. Lead Kaizen events and ‘trained-the-trainer’ for other Kaizen and Green Belt projects. Catalog Failure Modes and reduce failures – Enable Daily, weekly, monthly, and quarterly reporting for First Pass Yield and Internal QC for all 80+ product skews.

● Direct interface with customer complaints in TX and the Southeast. Reduce warranty response to a week and resolved most issues within 4 weeks.

Vallourec Drillpipe Products – Houston, TX -12/2008-3/2015, Process Engineer – Drillpipe Forging & Machining

● Process Improvement – Designed new forging tools for better pipe upset, which led to more stable set-ups, reduced downtime by 2 hours per change over.

● Projects Managed: development and installation of material handling automation – complete turnkey,

● Research & Cost-Analysis for proposed Capital Expenditures for new products/facility modernization.

Ford Motor Company Dearborn, MI - 1999 – 2008, 6 Sigma Black Belt, Manufacturing and Quality

● Black Belt Projects: Improved Significant Concerns and First-Time-Through. Reduced Warranty concerns

from 202/1000 Things-Gone-Wrong to 101/1000 TGW Completed Black Belt 6 Sigma training and started 2

BB projects that should save $500,000 in warranty claims.

● New Product Development: Vehicle Integration Engineer, F150 MY2008: Raptor F150 -Built and managed a

fleet of 60 prototypes, scheduled testing and maintenance.

● New Product Launch: Launched the Brand New State-of-the-Art Dearborn Truck Plant for MY2004. As Plant Engineer brought plant on-line to planned targets, through line speed management, process flow, model balance out.

● Production Supervisor of Final Area making current model, 12 months experience on the shop floor

● Powertrain Engineer – Structures RWD: Developed extension housing for 5-speed truck transmission for

Super Duty trucks and vans, saved $3 per unit by changing manufacturing process, total to $10 million savings to the life to the program.

Education -BSc Mechanical Engineering, University of Detroit-Mercy, Detroit, Michigan, 2002 U.S. citizen with passport, puedo hablar Espanol

Other Engineering skills: Tools/Skills: Global 8D, FMEA (Failure Mode and Effect Analysis) Process-FMEA and Design-FMEA, Process Controls, SPC, 6 Sigma, and Kaizen events; ISO 9001 and 14001 audits, TS 16949. TPS’s Safety-Quality-Delivery- Cost, Value Stream Mapping, 5S, Kanban, Poka-Yoke, Line Balancing, Visual Factory, Fishbone Diagrams. Pull Production, Taguchi Methods, Root Cause Analysis. Material Replenishment Principals: FIFO, JIT, Tip Level, Process Capability, Cpk-Ppk. DOE (Design of Experiments) MiniTAB, ANOVA, Operations, ROI, API, American Petroleum Institute, Operational Excellence, Syteline, OSHA, Gemba Walk, Finite Element Analysis, DEFORM software, T-Test, Tolerance Analysis Interval, Control Charts, ASME IX, Solidworks, VISIO, PeopleSoft, Fujitsu VPS, Experian, Digital Control Systems Interests: First LEGO League, Detroit Area Pre-College Engineering Program (DAPCEP), foster parenting.