Engineer Manufacturing
Resume:
David L. Weinberger, CMfgT
Pendleton, SC 29670
***********@*******.***
SUMMARY
25+ years’ experience in CNC production machining environments, with a consistent record of process improvements, cost reductions, methodical yet creative solutions to production issues, and sound project management.
EDUCATION
Clemson University Clemson, SC
BS in Mechanical Engineering May 1991 GPA 3.7/4.0
Successful completion of Fundamentals of Engineering Examination (EIT), April 1991
Post-baccalaureate study, Mechanical and Manufacturing Systems, May 1991-December 1992
TECHNICAL TRAINING
Sodick Vertical Sinker EDM Programming & Operation – Sodick USA, Schaumburg, IL
Solidworks Essentials – TPM, Greenville, SC
FARO Arm Portable CMM, AnthroCAM Measuring Software – FARO Technologies, Lake Mary, FL
Autoform CNC Press Brake Programming – Cincinnati Inc., Cincinnati, OH
Brother Tapping Center Conversational Programming – Yamazen Inc., Erlanger, KY
Okuma OSP5000 Lathe Programming – Gossiger Machine Tools, Dayton, OH
FANUC Custom Macro ‘B’ Programming – GE-FANUC, Charlottesville, VA
FANUC Mill ‘G’ Code Programming – GE-FANUC, Hoffman Estates, IL
MACHINE TOOL EXPERIENCE
Controllers: FANUC 0, 16, 16i, 18, 18i, 21, 21i, 31i; Okuma OSP5000; Fuji; Brother
Machine Tools:
Lathes: Emco-Maier; Hitachi-Seiki; Okuma; Mori Seiki CL20, CL200; Takisawa TT-200, TT-350, TT-2600G
Machining Centers/Mills: FANUC RoboDrill/Drill Mate; Okuma; Okuma-Howa; Brother Tapping Centers; SNK HF-4, HF-5; Komo VMC; Mori Seiki MV-40M, M25-FH; DMG-Mori NH4000 DCG; Kitamura 2XiF, HX400i-a; Doosan HP5100, DVM-40, Mynx5400, Puma V400, Puma V500
EDM: Sodick AG40L, AG60L, AG80L Sinkers, K-series EDM Drills; Beaumont FH40/6A-RTC Fast Hole EDM Drill
COMPUTER EXPERIENCE
Hardware: IBM PC
Software: SolidWorks (6000+ hours), AutoCAD, M-PACT Process Documentation Package, MS Office Suite
WORK EXPERIENCE
Synergy Solutions November 2018-May 2020
Contract Assignment – Eaton Aeroquip, Toccoa, GA
Manufacturing Development Engineer
Mid-High volume manufacturer of stamped and machined aerospace components
Responsible for shop floor support of flange machining operations, new part validation, and programming of CNC lathes
Developed and implemented macro program routines to ensure machine warmup when not run for extended periods
Developed macro program routines to store and import work shift data to improve lathe setup times
Implemented macro program routines to prevent machine crashes
Validated flange machining operations for parts moved to dual spindle lathe to add to existing production volume and increase productivity
Reduced cycle time for “one-hit” flange machining operations by 50%
Performed changeovers and setups on dual spindle lathe, bored/machined chuck jaws, wrote/modified programs
Trained operators and wrote work instructions for operation of dual spindle lathe
Wrote work instructions for various production machinery in facility
Alupress Inc. Laurens, SC December 2017-May 2018
Process Engineer
High volume Tier 2 automotive diecast and machined components supplier
Responsible for shop floor support, machine tool adjustments and setups, tool builds, and process and operations improvements
Improved misloaded part detection in machining centers
Optimized machine tool programs to reduce machining cycle times
Wrote work instructions for CNC file transfers to reduce need to keep all programs in CNC memory
Used knowledge of macro programming to troubleshoot machine programs
Woodward Inc. Greenville, SC October 2016-March 2017
Manufacturing Engineer
Mid-High volume manufacturer of gas turbine burner components and assemblies
Responsible for shop floor support of brazing and assembly processes, MRB dispositions, development of manufacturing operation sheets, and development of tooling for shop floor use
Belcan Services Group Greenville, SC September 2014-October 2016
Contract Assignment – United Technologies Aerospace Systems, Hodges, SC
Manufacturing Engineer
Mid-High volume manufacturer of gas turbine engine components
Responsible for support of multi-axis EDM drilling operations, tooling and fixture design
Developed setup methods for 5-axis CNC EDM drilling machine
Wrote programs for operation of 5-axis CNC EDM drilling machine
Set up 5-axis EDM drilling machine work cell; procured lifting/hoisting components, work tools, electrode setting hardware
Designed multi-facet graphite sinker EDM electrodes and developed solid modeling techniques for design of graphite electrodes for production of complex geometry features in turbine components
AFGlobal-Gloenco Greenville, SC December 2012-July 2014
Manufacturing Engineer/Tool Designer/Product Development Engineer
Mid-High volume manufacturer of power generation components
Responsible for support of all machining operations, tooling for new product roll-outs and prototypes, and routing maintenance
Designed and built workholding and test fixturing for micro-mixer fuel intake assemblies for machining operations, flow testing, and pressure testing
Developed processes, tooling, and fixturing for customer’s laboratory/prototype component manufacturing (all one-off or small-batch run components), including programming of electron beam welder
Rewrote electron beam welder programs for production gas turbine endcovers to produce higher quality welds, and included ability to perform cosmetic passes within the same program; reduced rework costs by $40,000/month
Wrote Renishaw probing routines for part setup, generation of work coordinates and coordinate rotation information to address inconsistencies in part setups and fixturing
Designed turning and inspection fixturing for aerospace components
Designed assembly tooling for powered installation of orifice plugs into gas turbine combustor endcovers
Designed fit & tack fixturing for turbine endcover standoff to improve consistency of weld process – incorporated 3-axis adjustment of parts to ensure accurate alignment
Designed and implemented fixturing improvements to eliminate true position fallout on gas turbine endcovers
Developed barstock usage improvement plan incorporating spindle liners and narrower cutoff blades to increase quantity of parts/unit bar length; increased parts/bar by up to 15% and reduced cycle times by up to 50%
Created and maintained routings for production and new parts
TWL Precision Ladson, SC September 2009-March 2012
Manufacturing/Methods Engineer
Mid-High volume manufacturer of precision machined turbocharger components
Responsible for machining operations on intake nozzle rings, gas collector housings, compressor crankcases, and turbine and bearing housings
Wrote macro subroutines to mistake-proof part changeovers, automatically generate and engrave sequential date coding, shift identification, and fixture face and pot locations for traceability, and automatically adjust cutter radius compensation based on tool life
Implemented torque wrenches and wrote procedures for consistent tooling assembly to eliminate scrap due to inconsistently assembled tooling
Reduced cycle times 10% for gas collector housing bottleneck operation through implementation of improved tooling following Pareto analysis of individual tool cycle times
Reduced consumable tooling cost by $24,000/year for gas collector housing bottleneck operation by implementation of special tooling
Reduced consumable tooling, setup time, and scrap costs by $35,000/year for midrange nozzle ring turning by replacement of special back-turning tool with modified standard tool
Set up and managed automated tool dispensing cabinet – worked with initial integrated supplier to place orders, manage inventory, restock cabinet, add tooling for new lines
Set up and calibrated Renishaw tool measurement lasers and part touch probes
Programmed autoloading robots for turning operations
Programmed laser marking unit to rework identification markings on midrange nozzle rings
PPAP’d and started production of laser marking of axial nozzle rings – coordinated modification of laser marking unit, programmed laser marking unit, wrote standard work instructions, trained operators
PPAP’d new production parts for nozzle rings
Unisia Steering Systems/ZUA Autoparts Oakwood, GA April 2001-May 2009
Manufacturing Engineer – Pump Machining
High volume manufacturer of automotive power steering pumps and rack & pinion assemblies
Responsible for machining operations of CP-1 power steering pump components
Specified, justified, procured, oversaw installation of, and started up machinery to briquette aluminum machining chips – increased revenue for aluminum chips by 56%, reduced operators’ chip disposal time by 75%, eliminated related safety issues, improved disposal area cleanliness, and virtually eliminated stormwater contamination potential. Wrote operation procedures and preventive maintenance tasks, and trained personnel in machinery operation. Submitted project for state environmental improvement competition.
Implemented scrap separation procedures with recycler to increase revenue for scrapped parts
Implemented form tapping of CP-1 pump discharge port – reduced tooling and machine usage costs by $41,000/year while eliminating contamination due to torn thread flanks; project earned honorable mention in corporate improvement competition
Reduced cycle time of rear cover seal face machining by 10%; reduced tooling costs by 90%
Procured tooling and programmed machining centers and lathe for new models of pumps
Designed fixturing for machining operations and gauging for production floor; set up fixturing and tooling for machining centers
Developed rework procedures for incomplete or damaged parts
Worked with Quality Engineering and suppliers to improve aluminum die castings
Implemented M-PACT software for document control of process flow charts, control plans, and PFMEA’s
Developed spreadsheet to track overall equipment effectiveness (OEE) for machining line; casing cell OEE increased to 81%, rear cover cell to 88% by reduction of unplanned downtime and improved cycle times
Member of Plant Productivity Cross-Functional Team – performed time studies to improve production line throughput for pump assembly line (reduced manpower requirements by 50%, doubled productivity metric of pieces/man/hour); created and implemented Production Line Supply Technician to increase line productivity
ISO/TS16949 Internal Auditor – Conducted internal audits of production lines and company procedures to ensure compliance with technical standard
Wrote operation procedures for machining operations
Kobelco America, Inc. Calhoun, GA March 1998-March 2001
Process Engineer – Fabrication Department
Manufacturer of hydraulic excavators and related fabricated components
Responsible for machining and press brake operations on all weldments and related component parts, as well as tooling, jig, and fixture design for all fabrication cells as necessary
Installed and set up fixturing for new excavator model machining operations
Programmed machining centers for machining of all models of travel motor housings and crawler frames, and made related locating hardware as necessary
Developed bore alignment test pin scheme to qualitatively inspect and assure bore alignments on all booms, arms, and center sections
Designed and built hydraulic bushing press for installation of bushings on booms and arms
Specified and procured special milling cutter for machining cheek cuts on boom tips
Initiated use of improved bushing retention compound – reduced compound usage while increasing amount of compound in joint: 30% cost reduction
Initiated cutting tool repair program for machining center tooling – reduced new tooling costs by $10,000 in less than 3 years
Procured, installed, set up, and programmed adjustable lower die for CNC press brake; designed, procured, and programmed upper dies for carbody plate bending
Programmed CNC press brake for all new excavator model crawler shells and carbody plates
Designed inspection templates for all press brake parts
Designed welding fit & tack jigs for all major weldments for new excavator models
Procured rigging hardware to move weldments and tooling
Worked with Quality Engineer and suppliers to resolve supplier-related parts issues
Initiated engineering changes to improve parts’ manufacturability
Led fabrication department Kaizen team to improve productivity of welding cells
Conducted time studies on all machining centers and welding robot systems
ISO9000 Certified Internal Auditor – conducted internal audits of company procedures and work instructions to assure compliance with ISO9001 standards
Wrote work instructions and process manuals for machining centers, presses, and other relevant areas in department
Kwikset Corporation Denison, TX November 1996-November 1997
Process Engineer
High volume manufacturer of die cast, stamped, and deep-drawing components for residential door hardware assemblies
Responsible for all machining operations on keyed knob and deadbolt cylinders and plugs, tapping of stemrose liners, machining of lever components, and drilling of bolts for deadbolt assemblies
Established Cylinder Fabrication team – procured all necessary hardware to adjust, operate, and maintain production machinery; sourced cutting tools; interviewed and onboarded personnel to staff (4) shifts on compressed schedule for 24/7 operation. Developed Quality Assurance and Safety procedures with appropriate departments. Developed machine operation and troubleshooting manuals.
Oversaw installation and runoff of (2) Mikron Multifactor rotary transfer machines for cylinder and plug machining
Worked with lubricant supplier and Plating team to find better cutting oil to improve parts cleaning and reduce cleaning, acid, and chromate tank contamination while retaining cutting tool performance
Designed snap gauges for spot checks of machined parts
Developed parts handling hardware, including container stands and parts collection baskets
Improved tool package for drilling and tapping of keyed lever components
Worked with company automation specialist to implement broken tool detection systems on manual stemrose tapping machines
Led team for improvement of die cast component machinability
Hitachi Automotive Products Harrodsburg, KY November 1994-November 1996
Production Engineer
High volume manufacturer of electromechanical and electronic automotive engine components
Responsible for all machining operations on alternator covers and rotor cores, distributor housings, idle speed control valves, and mass air flow sensor bodies
Designed, assembled, set up, and programmed vertical machining center fixturing for alternator covers, idle speed control valves, and mass air flow sensor bodies
Designed rotary transfer machine fixturing for mass air flow sensor bodies
Designed, set up, and programmed lathe fixturing for alternator covers
Designed boring bar holders for idle speed control valve lathe operations – reduced set-up costs by 50% by elimination of dependence on special boring bars
Developed tool package for idle speed control valve milling operations – reduced machining time 33%, improved CPk’s on all features to 1.35 or better
Developed grooving insert with tool manufacturer for mass air flow sensor body lathe operation – reduced machining time by 5s/part
Reduced machining time of alternator rotor cores by 10s/part while increasing parts/edge utilizing improved insert chipbreaker geometry
Specified, procured, and oversaw installation of parts conveyor system for mass air flow sensor body machining lines
Specified, procured, ran off, and oversaw installation of assembly machine for mass air flow sensor bodies
Coordinated installation and runoff of CNC transfer line for distributor housing machining
Member of Tool Crib Logistics Team – aided in development of tool crib procedures; procured hardware for tool assembly, disassembly, and presetting; assisted in development of tool regrind program with outside vendor
Conducted machine and process capability studies, and used SPC to troubleshoot processes
Participated in Kaizen activities to improve cell layouts and reduce parts handling
AMBAC International Columbia, SC July 1993-July 1994
Associate Manufacturing Engineer
High volume precision machining assembly job shop for ABS brake systems and fuel injection components
Responsible for all machining operations on Caterpillar HEUI series single unit fuel injector components
Designed, oversaw construction of, and developed process for high pressure fluid deburring machine
Designed conveyor between centerless grinder and brush deburring machine
Assisted in design of special drilling and deburring machine
Improved productivity of drilling and deburring machine by 20% while reducing tool package cost by 50%
Developed tool package for CNC drilling machine and assisted in its programming
Worked with other engineers to improve rough and finish seal face grinding processes
Developed specifications and layout for climate-controlled gauging and assembly room
Worked with purchasing and tool crib to optimize tool inventories for entire product line
Set up operation and upkeep of alkaline de-rust station and maintenance schedule for process/final washer
Conducted machine and process capability studies, used SPC to troubleshoot processes, performed time studies to update standards, participated in FMEA reviews
AFFILIATIONS: Society of Manufacturing Engineers, Historical Construction Equipment Association, American Mensa (chapter president January 2006-December 2007)
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