MAX R. BANAKAR

** *****

Rancho Santa Margarita, CA 92688

C 206- 605-7671

adu7a5@r.postjobfree.com

SUMMARY

• Senior level Project Engineer with experience in the regulated industry in manufacturing engineering, operations, production, global sourcing, cost improvement, P&L, quality improvement, GMP, and Project Management.

• Proven success building and directing lean winner entrepreneurial teams in all activities associated with PDI (Product Development Introduction) and product life cycle management.

• Expertise in Design of Lean Manufacturing system, Cost reduction, product life-cycle management, and margin improvements through lean, Toyota Production System (TPS), and DfX.

• Excellent communication, Procedural improvements/streamlining, and reorganization.

• Global supplier management (Mfg. process improvement and approval), sourcing, and negotiations (based on target cost and should cost analysis).

Professional Experience:

Parker Aerospace 4/2019 - Present

Fluid System Division

Irvine, CA

Sr. Manufacturing Engineer / Project Engineer Mfg.

Industrialization of new product (NPI) to meet delivery time and the target cost. Created PFD, PFMEA and Control Plan for new products to mitigate quality issues. Managed Capacity analysis vs. demand with supply chain and planners. Created Mfg. and capacity plan and managed tasks related to industrialization of new products for our customers. Managed and completed all buy-tools/fixtures/test boxes and CapEx custom automation equipment for NPI production. Present to the leadership and customers the project status and production readiness. ISO9001, AS13004. Implemented new production vertical integration for new Airbus product.

Active participation in meeting with our customers (Collins, Airbus, Boeing) in different gates of the project.

Banakar Industrial Consulting Services (BICS) 6/2018 - 3/2022

Specialize in production lay-out, process optimizations, cycle time reductions, automation, C/B analysis

Customers: Google, Hilti, Fender

Rancho Santa Margarita, CA

Boeing (consultant) 6/2018 - 12/2018

Everett, WA

Provide analysis and optimization of the mfg. a process on 777 HBL interior (composite material)

Analysis data on IPs and presented to the production manager

Provide Champion Recipe for improvements in production set-up and changeover by analysis VA vs. NVA

Provide trade analysis (ROI) of new tools/equipment on manual operations and present cost/benefits analysis and IRR.

Applied Industrial Engineering techniques and decision tools to promote and assist in implementing changes in manufacturing, engineering, and service operations.

Spacelabs Healthcare (ISO13485) 3/2016- 12/2017

Snoqualmie, WA

Sr. Manager Operations Engineering (full time)

Reorganized and managed department 15 engineers (Mechanical and EE), and achieved completion projects on time and budget for sustaining NPD projects by 98%. Set up the new production line of future electromechanical devices.

Managed Master validation plan and responded to compliance, Corrective Action and, Prevention Action (CAPA). Successfully managed transfer parts/products to our plant in WA from offshore facility. The root cause analysis and provide solutions. Completed remediation as requested by FDA.

Worked with the design team for new Mfg. Processes and Design for manufacturability (SOW, DFM). Completed DFMEA, PFMEA and, APQP for new products with the project team.

Worked with our suppliers to optimize (lean) manufacturing processes to meet the target cost and quality, improved GPM by 3 points through “Should Cost Analysis” on parts.

Provided supply chain group with DfX training and cost analysis.

Managed and successfully achieved UDI implementation, 3rd edition labeling, and Metro for our products on time.

Successfully transferred production line in Suzhou, China to the USA and reached the target margin goal. Establishing Operation Engineering budgets and managing operations to meet financial targets.

Philips, Health Tech (ISO13485) 1/2013-3/2016

Bothell, WA

Sr. Manager, Principal Cost Engineer production & operations (full time)

Managed cost savings projects, lean and DfX projects. Successfully achieved saving goals in each product line.

Implemented by new manufacturing processes using lean principles (5 phases).

Worked with the design team and product engineers to optimize the design and manufacturability of Sonicare products through process optimization to improve yield.

Reviewed the cost of goods worldwide against our target and provided and implemented solutions to improve GPM (improved 8% for 2014/15)

Reduced COGS of products through automation (labor) and “should-cost analysis” and cost modeling on purchased parts (BOM), and labor and OH for OEM products.

Work with suppliers, Injection molding (PC/ABS, 4K Hot manifold molds), sheet metal processes and, CNC machining to improve quality of mfg. Process. Cost negotiation based on an open book and should-cost analysis.

Provided analysis on circular economy for Sonicare products.

Worked with the procurement team and supplier chain to improve supplier selection and process optimizations (VSM).

Driven product quality and continuous improvement. Responsible for improving the unit cost of the product.

Leviton Mfg. Co., Network Solutions Division (UL) 3/2000 – 11/2012

Bothell, WA

Manager of Manufacturing Engineering / Document Control (full time)

Lead and Managed a team of six manufacturing/Industrial engineers and two managers in document control.

Responsible for developing manufacturing processes for all new products through the NPI process and transitioning to production.

Managed sustaining activities for process improvement (kaizen) for the existing products.

Manufacturing cost analysis (BOM, Labor & fixed and variable OH), and implement annual cost savings goal and monthly report (over $2,000,000 on annual cost savings per year since 2001).

Responsible for new capital equipment selection, buy-off (validation and verification), and engineering economic analysis (ROI, IRR).

Responsible for improving the cost of products COGS and improve GPM

Primex Aerospace Co (General Dynamics) 2000-2001

Redmond, WA

Sr. Process Engineer (Contract)

Responsible for the implementation of manufacturing processes for the airbag division.

Successfully design and implemented new lean Mfg. system for fire suppression system for Ford Crown Victoria.

Participated in supplier selection for parts and components. Achieved target cost through my negotiation with vendors.

Design and purchase capital equipment and completed the buy-off procedure and transferred to the production facility.

Implemented all documentation such as Process Flow, PFMEA, and PQCT.

Inflation Systems, Inc. 1996-1999

Moses Lake, WA

Mfg. Engineering Superintendent (full time)

Responsible for manufacturing projects for driver/passenger-side inflator lines.

Managed seven manufacturing engineers. Completed projects on time and within budget.

Coordinate new products with manufacturing and design teams and be responsible for implementing new production processes to meet target cost and cycle time.

Prepared customers documentation for Process flow, PFMEA and, Process Sign-Off (PSF), and completed UL audits.

Implemented a lean manufacturing system for new and existing products from prototype concept to high volume production based on Toyota Production System. This improved non-value activities on the production floor by 25%.

I was responsible for concept design, acquisition, and implementation of the fully automated production system. Control and maintain the manufacturing process for different models of inflators. Cost reduction through automation, cycle time reduction (over $700,000 per year).

Education

-Master of Engineering Management, St. Martin’s University

Lacey, Washington, GPA 4.0. 1992

- Bachelor of Science in Industrial Engineering, University of Central America (UACA),

San Jose, Costa Rica, Cum Laude. 1985

- Certification on Design of Manufacturing Systems: Lean Mfg. The system, Toyota Production System (TPS), six sigma approach, Theory and Practice, Massachusetts Institute of Technology (MIT) Cambridge, Massachusetts. 1998

- DfX certification, Philips

Philips E2E (End to End), Lean Leadership Training (Green Belt).

-Leadership Training for Managers, Dale Carnegie Training, 2010

-Completed the “Toyota Production System” at ISI Plant in La Grange, GA, 1998

-Completed training on Lean Mfg. The system in ISI and Toyota plants in Japan. 1998

AWARD (7 US patents)

-US design patents of D521941 (Industrial Connectivity Cable Connector), D530286 (Connector Boot), D543947S, D554067S and D555597 (Connector Housing), 7547227 (laminated label), and D592045

-Knowledge in application software: Minitab, MS office, AutoCAD, ENOVIA, CATIA, AS400, Oracle, SAP, STORM (Industrial Engineering SW).

Fully bilingual: English, Spanish

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