Process Engineer

Micheal A. Hutnik

San Jose, CA 713-***-**** adc0ro@r.postjobfree.com

Objective To secure a dynamic, challenging opportunity that contributes to the growth of the business through quality control, production, & engineering from various global industries. Profile Recognized as a creative, resourceful thinker—strategic planner and problem solver. Proven track record of strategic vision in regard to production, quick delivery and design for manufacturability. Delivered quality controls and enhancements to proactively address problems and improve product, manufacturing flow, customer satisfaction and bottom-line results. Proficient in lean manufacturing and 5S in regard to automotive, aerospace, metal fabrication, machining and injection molding. Core Qualifications

IQ, OQ, & PQ Validation

RJG

Injection Molding

Robotics &

Automation

Extrusion

Quality/GD&T

Six Sigma & Iso

Leadership

Mechanical Engineering

Professional Experience MOS MEDICAL San Jose, California

Senior Process Engineer November 2018-Current

Medical & Electronic OEMs

Sustained IQ/OQ/PQ validation processes for medical companies such as Allergan, Abbott, Thermofisher, and Concentric

Studied polymer behavior with materials such as HDPE, PP, ABS, SAN, PS, PC, PBT, Nylon, GF Nylon, TPU, TPE, POM/Acetal, PPS, PEEK and many custom compounded engineering resins

Established design of experiments utilizing Nautilus & mold flow analysis software

Certified in Arburg machinery and robotic equipment respectively-- completed in Irvine, California

Proficient in Yushin robotics & Keyence software while developing technical programs with vast volumes of inputs and outputs

Created precision molding processes to ensure parts within .0005” flatness via multiple cavity tooling

Proverbial with SELOGICA control systems, Wittman Battenfeld conveyors and sprue pickers, Motan proportionate loaders, Conair thermolators and temperature controllers.

Assisted in the design of end of arm tooling with multiple vacuums, grippers, de-gating stations, cylinders, pneumatics, and 3D printed prototypes

Participated in weekly design and engineering reviews for upcoming products to optimize costs, ensure manufacturability

Effective in pad printing, sonic welding and universal robot secondary operations

Defined geometric dimensioning and tolerancing principles with utilization of all metrology utensils

(micrometers, boring bar, optical comparator, height gage, radius gages, calipers etc.,)

Tooling ranged from 1-32 cavity hot runner systems, valve gated, multiple core pull, 3 plated, insert

& over molding utilizing 28T-500T machinery

2 Class 10,000 clean rooms (ISO Class 7) ISO13485:2016 Certification, cGMP compliant GTI-USA Stafford, Texas

Process Engineering March 2017-November 2018

Dept. Manager

Specialty Reinforcement Systems

Developed processes using mold flow analysis, cavity balance, gate freeze, viscosity, melt flow and rheology methods

Utilized Negribossi, Tayu, Nissei, Haitian, Van Dorn, Arburg, Milacron and Toshiba vertical and horizontal IMM

Manufactured and extruded round duct specifically for each customer while cutting duct to specific length or coils.

Auxiliary equipment programming such as 5-axis Styrama end of arm and Fanuc robotics

Streamline production processes through tool validation and IQ, OQ, & PQ methods.

Evaluated machine capability, inspected and safely troubleshot to detect cause of failure

Well-rounded specialist in injection molding tooling design including gating, venting, over molding, and complex actions

Expertise in implementing cost saving measures to achieve substantial reduction of man-hours, production cost, raw materials and energy consumption

Tooling ranged from 1-64 cavity hot runner systems, multiple core pull, two shot molds ranging from 100 to 1300 tons.

Instructed daily meetings related to new product development, inventory, material requirement planning and finances.

Interviewed potential employees, scheduled staff, evaluated performance and made recommendations for promotions.

HOUSTON PLASTIC PRODUCTS Houston, Texas

Molding Manager March 2014 to March 2017

Sr. Process Technician

Technical Operations

Safety Coordinator

Adept in scientific molding utilizing Van Dorn- Demag (1970 models) to 2016 Arburgs, but not limited to TMC, Toshiba, Engel and Milacron.

Managed 4-6 new projects yearly, from concept to final (totaling $1.5 of annual revenue)

Resolved ECO changes and/or dimensional concerns with tooling modifications, and fixtures

Trained technicians, defined quality inspection criteria to produce medical components within

.0005 tolerances via the Class 8 clean room.

Calibrated advanced scanning equipment such as Keyence and Smartscope technology.

Reduced non-conformances (return material) by 91% in first year of quality management increasing customer satisfaction and profitability.

Conducted tooling and part validation processes such as IQ, OQ, and PQ, familiar with CPK studies, Ishikawa diagrams.

Provided signature prior to shipping product, first article approvals, inspection reports, and certificates of conformance for companies such as Schlumberger, GE, and Baker Hughes.

Data and document controller compliant to ISO 9001:2008 standards

Scheduled purchase orders and upheld weekly production meetings to review material allocations, expedited deliveries, secondary operations (machining and assembly) and customer service.

Increased on-time delivery to 98 percent from 61 percent (lowering salary costs 26.6%) with valued customers through automation, decreased cycle times, and developing setups.

Coordinated monthly management safety PowerPoints to continually improve and train operators and personnel on OSHA requirements.

TEXAS INJECTION MOLDING Pasadena, Texas

Production Manager/Technician April 2012 to March 2014 World class custom injection molding

Led secondary operations to mechanical assembly, packaging, printing, machining & sonic welding.

Executed mold design changes, new molds, and preventative maintenance.

Directed and managed a fast paced manufacturing environment with 80+ employees.

Achieved company goals to surpass production expectations and instill vision while maintaining quality, safety, and customer service.

Restructured facility to address business growth and production goals while reducing labor, materials and costs.

Doubled monthly revenue and production efficiency while growing to 17 injection molding machines from 55 ton to 750 U.S. tons with a maximum 115 oz. shot capacity.

Established a team spirited environment through a positive and proactive leadership style.

Products and services included oil, electronics, energy, food and beverage, and medical fields.

Review of industrial design concepts and models while giving engineering expertise in selecting the best cost effective plastic resins for the product application.

Analyzed payroll costs and productivity reports to implement best procedure, technology, and practices.

COASTAL PLASTICS/CLASSIC TOOL Alvin, Texas

Manufacturing Manager Sept 2009 to April 2012

Process Technician

Injection Molding & Tooling

Implemented a quality control system which included quality control documents, spreadsheets, inspection reports, final audits and control samples.

Setup up manual mills and CNC for secondary operations.

Reduced scrap rate from thirty-percent to less than one-percent.

Responsibilities included production, quality, shipping, purchasing and maintenance.

In charge of all employees in the manufacturing environment.

Increased revenue and production efficiency exponentially; while decreasing payroll, scrap, quality issues.

Maintained a flexible but consistent schedule to meet a high demanding custom market.

Delivered product on time-every time.

Developed customer relationships leading to higher product outputs.

Always met and exceeded customer expectations.

FISHER DYNAMICS St. Clair Shores & Troy, Michigan

Quality Technician/Prototype Division 2007 to 2009 Automotive industry premier supplier of seat mechanisms

Ensure the process quality control activities are in compliance with company/client specific requirements

Inspect prototype, short-run, and production parts conforming to blueprint specifications using GD&T

Saved company funds through non-conforming detection audits prior to shipping to final customers

Implemented first piece inspections, in-process and final audits on single or assembled items

Conducted precision measurements using tooling such as micrometers, calipers and dial gauges

Problem solved issues with prototype parts to develop leading industry seat control devices on CNC lathes

Knowledgeable in ISO 14001 & ISO/TS 16949, PPAP, APQP, GD&T, FMEA and G- Code programming

DRAKE ENTERPRISES Clinton Township, Michigan

Quality Engineer 2004 to 2007

Tier 1 supplier of engine & transmission components

Inspected blueprints and bill of material to correctly assemble, orientate and fasten components for Eaton transmissions using pneumatic hand tools (Class 8 Heavy Duty Trucks)

Piloted final audit, in process and certified material for assembly department

Operated CMM (Coordinate Measurement Machine); Mitutoyo CMM with COSMOS-3 with geo-track 2.4 R9 software with scanning capability.

Calibrated & maintained gauges annually

Implemented and created work instructions for new cells

Devised functioning internal scrap system, designed to save the company money.

Directed poke yoke for automated robot (Fanuc) gear shift housing assembly

Documented receiving inspection for heat treat, chrome, welded levers and shafts

Graphed and tabled all quality issues found to prevent and place corrective action in Microsoft Excel

Ordered inventory and completed annual year-end inventory process.

Train, tracked and scheduled 10-15 employees and communicated frequently with suppliers

Process starts from raw materials and continues through extrusion, welding, painting and finishes with a complete assembled product

Accomplishments

2011 Chrysler Quality Performance Award Daimler

Chrysler Gold Award Outstand Supplier Eaton

Ford Motor Company Q1 Quality Award

International Navistar Award

Education MACOMB COLLEGE – 2005 to 2009

(Mechanical Engineering & Business Administration Curriculums)

*Personal and Professional References available upon request.

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