Brian Michael Zuehlk:

**** ********* ****, ******* ** 48367 Mobile 248-***-**** add1m9@r.postjobfree.com Highlights of Qualifications:

• 25 years of experience, with a strong understanding of GMAW and resistance weld parameter development. (Aluminum/Steel)

• Strong Fanuc robot programming skills, including initial set up, to production support. (Welding, Material Handling, Dispensing)

• Ability to read and understand a welding oscilloscope and how it pertains to weld quality and repeatability.

• Familiar with: Fanuc, Bosch, WTC, Emhart, Nordson, Lincoln, Miller, Fronius,

• Utilized metrology equipment such as: wet saw, disc polishers, etching chemicals, and microscopes for cross section evaluation.

• Understanding of BIW specifications. GMAW, GMAB, FCAW, RSW, FDS, SPR, Laser, per AWS specifications.

• Implemented TPM plans to include preventative, predictive, and autonomous maintenance routines.

• Performed PFMEA and Kaizen activities on weld lines and support equipment, using WCM methods.

• Performed time measurement and line balancing studies, ROI calculations.

• Program management of new weld line launches, including budget, RFQ’s, manpower, and onsite equipment.

• Developed training courses for union personnel, and implemented classes throughout the US, Mexico, and China.

• Possess great electrical skills 480vac – 24vdc with an understanding of Allen Bradley PLC logic.

• Designed and built many welding and specialty assembly machines.

• Managed spare parts, tool crib inventories, and kept track as a KPI (sales vs. maintenance costs)

• Manual MIG, TIG and arc welding, proficient on a mill, lathe, surface grinder or any other tool room equipment.

• State of Michigan certified as Firefighter/Emergency Medical Technician. Active member of the Coast Guard Auxiliary. FCA: 01/2020 - Present: Maintenance Manager: Currently launching the new Jeep Cherokee WL program.

• Management of UAW skilled trades and contractors (Electricians, Millwrights, Pipefitters, and System Specialists)

• Review of over 2000 standard maintenance procedures for accuracy, along with 1200 machine ledgers.

• Overseeing the build of a robotic training cell, and provide training to the skilled trades. Magna: 12/2017–12/2019: Maintenance & Facilities Manager/Weld Engineer Responsible for 17 direct reports across three shifts with 130 robots. I was brought in to help turn the plant around. When I started, we were running at 60% OEE, we now run at 85%.

• Fanuc robots, Nordson dispense, Emhart stud welding, Bosch/Lincoln weld controls, ATI tool changers, Milco and Centerline guns.

• Developed weld parameters for RSW, GMAW, GMAB, and projection welding processes.

• Implemented TPM plan to include preventative, predictive, and autonomous maintenance routines. Which in turn brought machine downtime from 20% to < 5%. Ultimately improving MTBF and MTTR. Tracked all open issues.

• With weld parameter improvements, Emhart stud failures went from the biggest issue in the plant to no issue at all.

• Managed a multi-million-dollar maintenance budget, keeping repair and maintenance costs less than 1.3% of sales.

• KPI’s: Equipment and Facility PM’s, Work Orders, MTBF/MTTR, Sales vs. Maintenance Costs.

• Line buy offs, developed machine standards, attended APQP and PCN meetings.

• Corrected and reimplemented red rabbit error proofing plant wide. Quality went from the worst to the best within Cosma.

• Familiar with trouble shooting tools such as 5S, 5 Why, Fishbone, Pareto Analysis Charts, daily quick response meetings.

• Coordinated outside contractors for new line installations and facility improvements.

• Knowledge of ISO 9001/IATF and internal auditing. General Motors 08/2014 – 12/2017 Weld/ Robotics Engineer: Lead Weld Engineer on the development and implementation of aluminum welding. This includes process design through production support and training.

• Weld development on aluminum and advanced high strength steels. (WTC weld controls)

• Supply chain material approvals, including weldability, and correct coatings weight such as Alodine.

• Studied the results of surface resistance at the faying surface, and how it directly correlates with the weldability of aluminum.

• Aluminum MRD tip dressing implementation, as well as automated weld cap changers. (Changer Dresser, JEC Copperhead)

• Worked on the development of many new patents, including the resistance welding of steel to aluminum.

• Responsible for training union plant personnel on aluminum welding and tip dressing practices.

• Provide input for next generation robotic software development where welding is involved.

• Lead problem solver for the production plants, replicated issues in the lab, and implemented the solution in the plants.

• Trained Tier supplier weld engineers on the why and how of aluminum welding.

• Tested next generation robotic software before the release to production. Katcon USA, Auburn Hills Mi. 09/2011 – 08/2014: Maintenance & Facilities Manager: this included the role of Weld Engineer, Robot Programmer, Controls Engineer, and Electrician. Launched Katcon’s first North American plant, from an empty building, through the start of production. Installed Fanuc dual arm MIG welding robots utilizing coordinated motion with a 7th and 8th axis, Allen Bradley PLC and HMI controls. Hired and built a successful maintenance team and implemented TPM routines. Developed stainless steel GMAW welding parameters. (automotive exhaust systems)

• Project management from concept through production. RFQ’s, contractors, onsite equipment, etc.

• Machine installation including electrical wiring, plumbing, robot and weld schedule development.

• Reduced the downtime of equipment and followed through on daily maintenance tasks to ensure machine uptime.

• Track downtime and equipment failures with proactive measures to eliminate future problems.

• Organize and conduct troubleshooting on the breakdown of machines, equipment, tools and fixtures.

• Planning and scheduling of maintenance work orders, held training classes for maintenance personnel.

• Main contact for MIOSHA, Fire Department, City of Auburn Hills and the DEQ.

• Purchase, maintain and control all spare part inventories within assigned budget.

• Develop and work within the annual budget along with aggressive cost reduction in all areas of manufacturing.

• Create Lock Out Tag Out program and ensure policy enforcement.

• Coordinated bulk gas installation, EFI lighting, HVAC system, sprinkler upgrades, negotiated weld wire and inert gas contracts. Sodecia/General Motors, Lake Orion MI 03/2011 – 09/2011: Maintenance Supervisor, Weld Engineer, Robot Programmer: Launched Sodecia’s robotic weld lines inside the General Motors Lake Orion plant. Used a mix of Fanuc and Nachi robots, Nelson and Emhart stud welders along with material handling end effectors. All equipment used Allen Bradley machine controls

• Weld quality improvements on press hardened steels.

• Reduced robotic cycle times, built preproduction prototypes, helped with zone layouts, and component configurations.

• Spare parts, equipment purchasing, RFQ’s

• Coordinated skilled trades contractors on weld line installations.

• Trained machine operators and maintenance personnel, on correct machine operation or advanced robot programming. Hamlin Tool and Machine, Rochester Hills MI 01/2004 – 03/2011: Maintenance Manager, Weld Engineer, Robot Programmer: Maintained and repaired the robots, resistance welders and stamping press lines. This included any pneumatic, hydraulic, electrical, or mechanical problems.

• Hired to reduce the scrap rate on the robotic MIG welding line which was more than 8%, within 6 months I had it less than 1%.

• Resolved a poor design problem on four identical assembly machines. To keep up with production requirements all four machines ran a total of 320 hours a week. I built a single machine that would allow one operator to achieve the production requirements in 40 hours.

• Designed and built a quick-change scrap chute machine for a stamping press, this drastically reduced set up time.

• Worked with the OEM on projection weld nut designs.

• Built an automated resistance welder capable of welding 4000+ weld nuts a shift onto differential covers. To date 6,000,000+ parts have been manufactured without an issue.

Die Tech Tool, Imlay City MI 10/1993 – 12/2003: Weld Technician, Toolmaker, Machine Builder, Die Repair Supervisor

• Managed all resistance and GMAW welding including spot, nut and stud.

• Responsible for the design and build of all resistance weld tooling.

• Designed and built several large automated resistance weld cells.

• Maintained and repaired the presses, robots, resistance welders and other assembly machines.

• Built single hit and progressive dies from the 50 to the 400-ton range including checking fixtures for every die built.

• Extensive progressive die build background.

Education:

• 1994 - 1995 Oakland Community College - CNC Machining.

• 2004 Fanuc Robotics - Robot Programming, Lincoln Electric – Arc Welding

• 2012 Allen Bradley - PLC Programming.

• 2014 - 2015 Certified by the State of Michigan as Firefighter/ Emergency Medical Technician. (Addison Twp. Fire Dept.)

• 2016 - 2017 Macomb Community College - Electrical Engineering.

• Active member of the Coast Guard Auxiliary and the Detroit Power Squadron.

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