Industrial Engineer Manufacturing

James A. Klingaman

860-***-**** http://www.linkedin.com/in/jamesklingaman *****.*********@*****.***

OBJECTIVE

Secure a position where I can use existing skills and develop new skills to provide exceptional manufacturing support for improved producibility and product quality, while reducing Time-to-Market and, ultimately, Customer Satisfaction.

SUMMARY

Manufacturing / Industrial Engineer with strong expertise in applying Lean Manufacturing principles and driving extensive cost savings through innovative process and product improvements. I possess the manufacturing experience required to support New Product Development for numerous sophisticated products including Automotive, Fuel Cell, Aerospace and Medical Devices. Recognized for creative process and problem-solving abilities and for overcoming obstacles by utilizing mechanical and statistical aptitudes.

Training and Skills

Lean Six Sigma (Certified – TPS based)

Issue Resolution,/Root Cause Analysis

Ergonomic Stressor Assessment

Statistical Process Control (SPC)

Engineered Problem Solving / Red-X

Value Stream Mapping

PFMEA Development

Design for Six Sigma, DFM/DFA, DMAIC

SAP, JDE, Oracle and TEAMCENTER

Capacity Analysis

Capital Equipment Acquisition

Work Measurement

Minitab Statistical Analysis (Cpk/Ppk)

Industrial Safety Standards

PROFESSIONAL EXPERIENCE

Contract Industrial Engineer

Contract Employee to IET (Industrial Engineering Technology, Inc.) Toledo, Oh 6/22-Present

Key Role: Industrial and Manufacturing Engineering technical support for IET client projects

Delay studies and process improvement recommendations automotive supplier.

Assembly process development, tooling and layout recommendations for commercial E.V. manufacturer

Contract Senior Manufacturing Engineer

An Atos Employee assigned to DePuy-Synthes Spine div. of Johnson and Johnson, Raynham, MA 08/18-03/22

Key Role: Manufacturing process support for Medical Device and Surgical Instrument development.

Process Verification/Process Validation support.

Design Transfer, PFMEA/Risk Assessment, DFM/DFA, Manufacturability of Design CTQ features.

MDD/MDR Change Order support/COGS, Stability Metrics coordinator.

Root Cause/SCAR/CAPA/Problem Solving and Issue Resolution support.

Industrial Engineer

SmartPak, Inc., Plymouth, MA Contract Engineer 2014 – 2015: Direct Employee 2015 to 2018

Key Role: Project Management, capacity, utilization and machine loading analysis.

Work measurement analysis Equine Supplement Production.

Standard Procedure development and Work Measurement processing.

Project Manager – New Process/New Equipment Introduction

Improved production productivity by 60% two consecutive years resulting in 2.5x increase in output.

Achieved Lean Six Sigma Black Belt certification and Lean Facilitator certification.

Project Manager for WCS implementation for Fulfillment, Equine Production and Canine Production.

Contract Industrial Engineer

ZIMMER, Inc., Warsaw, IN 2014 – 2014 Contracted Assignment Completed and Closed

Key Role: Time Study development, capacity, utilization and machine loading analysis.

Work measurement analysis for multifaceted machining and manufacturing processes for medical devices.

Standard Procedure development and Work Measurement processing.

Performance review resulted in contract extension.

Senior Manufacturing Process Engineer

HYPERTHERM, Lebanon, NH 2012 – 2013

Key Role: Embedded in Design team to provide DFM/DFA and process development plans for assembly.

Developed PFMEAs- prepared 4-Panel charting and Process Control plans- all Manual System’s products.

Facilitated Beta Builds and NPI Launch efforts and Operational Process Verification and Validations.

Installed and programmed DC Servo assembly tooling to control torque setting for Critical-to-Quality joints resulting in improved first-time quality, streamlined quality documentation and $50,000 in savings.

Conceived, organized, and successfully led Corporation-wide transition from Phillips- type to Torx-type fasteners for Ergonomic, Quality and Cost improvements resulting in savings of over $35,000 annually.

James A. Klingaman Page Two

Contract Industrial Engineer at the TIMKEN Corporation

DAVIS ENGINEERING AND I.T., LLC - contracted to The Timken Company, Keene, NH 2011 – 2012

Key Role: Data updating and system entry Industrial Engineering Analyst

Update routings and Bill of Materials in TEAMCENTER and enter releases into SAP.

Assist in reducing documentation backload and improve routing releases and On-Time delivery.

Senior Industrial Engineer

UNITED TECHNOLOGIES CORPORATION, Sikorsky Division, Coatesville, PA 2009 – 2011

Key Role: Build Activity manager for S-92 Completions Hangar

Developed Lean Standard Work for the S92 Large Commercial Helicopter Completions Hangar.

Developed Lean processes for Interiors, including Upholstery, Interior Panel fit out and Interiors installation.

Prepared the manufacturing schedules for NPI of ‘Next Gen’ small commercial helicopter Final Assembly.

Planned schedules and set the requirements for arrival of assembly components with Supply Chain for "Just in Time" assembly processing in a union environment.

Improved overall operational production flow an average of 720 man-hours per aircraft model by changing build style from static "battleship" build process to progressive, Lean build, "One piece flow style" assembly methodology.

Staff Analyst / Manufacturing Engineering Lead

UNITED TECHNOLOGIES CORPORATION, Power Division, South Windsor, CT 2007 – 2009

Key Role: Lead Manufacturing Engineer for NPI, Plant Re-facilitation and process development in Union Shop.

Spearheaded product development with Design Engineering, developed assembly processes, determined capital acquisition requirements for plant re-facilitation, and managed those projects to ready plant for new 400kW Stationary Fuel Cell launch.

Led the efforts to effect cultural change from an R&D mindset to a full production manufacturing environment.

Improved program metrics by 20% for stretch goals regarding cost, timing and production capacity by developing methods for module integration and material movement. Recognized with 100% executive approval for conceptualizing and managing over $4M in Capital Asset projects.

Reduced manufacturing costs by $2.7M through development and implementation of innovative rail and dual turn-table system to move 60,000 lb. fuel cell through ‘U’ shaped assembly facility.

Advanced Manufacturing Engineer

GENERAL MOTORS CORPORATION, Warren, MI 1993 – 2007

SATURN CORPORATION, Madison Heights, MI 1993 – 2001

Key Role: Manufacturing lead for development of assembly processes for future vehicles, including Saturn Vue, (Standard and Hybrids,) Saturn L Series, Saturn Ion, Pontiac GTO, and Cadillac and Saab crossover vehicles.

Drove product and lean process development by providing tooling and tooling accessibility metrics, ergonomic stressor mediation analysis, and tooling and material anti-proliferation strategies.

Achieved numerous cost reductions of 10% or better by developing and implementing process improvements in a UAW Union environment.

Prevented a several month delay to Launch Date for High Performance Grand Am by developing and installing a unique Hood Assembly Installation system under budget and on accelerated schedule (Design concept-to-implementation was done in less than 10 weeks; normal accepted development lead time was 6 months).

Provided a cost avoidance of $250K for an additional assembly carousel by developing an alternative assembly process to increase Lift Gate production by 25%.

Saved over $500K through Capital Tooling initiatives for Doors Removal, Doors Re-install and sub-assembly line Door carrier / assembly fixtures.

Saved over $1M and $500K, respectively, for major product change by conceptualizing, coordinating design efforts, and implementing conveyor carrier projects for two separate and distinct conveyor systems.

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