MANNUFACTURING MANAGER/ENGINEER

Manager and Engineer/ Continuous Improvement/Lean Operations/Project Manager

Very successful leader in Manufacturing Operations of all types. Developed lean processes that reduce cost of production. Have developed processes that increase productivity while increasing quality. Project Manager in new construction, and equipment installation. Demonstrated the ability to look over current manufacturing processes and improve them for better yields and quality.

CORE COMPETENCIES

JIT

Kaizen

Quality

Supplier Quality

Roll Forming

Stamping

Metal Pretreatments

Coatings on Plastic/Metals

E-coat

Stamping

Project Manager

Lean Mfg.

Toyota Production System

Welding

Porcelain Enamels

Product/Equipment Design

OSHA 10 Certified

Wastewater

Supervision

Equipment Utilization

FMEA Document Creations

PROFESSIONAL HISTORY

PRODUCTION MANAGER

Magna International Corporation

I am currently a Production Manager at Magna, working in a new division called MEVS (Magna Electric Vehicle Systems) which is a part of Cosma. I oversee startup and debugging a new e-coat system at a new facility in Michigan.

I am responsible for setting up wastewater systems and am working on ways to reclaim wastewater and repurpose it into our system.

MANAGEMENT CONSULTING

I have been doing various consulting work for companies since April/2019 to present. I have assisted such industries in automotive, medical, and consumer products.

I am currently working with automotive suppliers on improving their painting process and injection process.

Developing processes to follow to reduce dirt and other defects in class 1 parts, also assisting molding department to reduce sinks and other defects in plastic molded parts.

Energizer:

Responsible for reorganizing their current “GATE PROCESS” to prevent past mistakes and make it universal throughout their product lines.

Setting up FMEA’s for use in all processes

Working to establish a more robust quality check system along with adding some problem-solving procedures for their process and to validate their supplier’s process

Consulting various companies on how to improve their capabilities and quality during the coved period.

Johnson and Johnson/ Consultant April 2019 to December 2019

Based in Cincinnati, Ohio, Traveled to Utah 3 weeks a month.

This facility was purchased by Johnson and Johnson 1 year before my start.

Managed the equipment purchase to transfer operations from manual to automatize system.

Set up robot to use to spray surgical products

Changed equipment that was purchased before my start. Changed from electrostatic equipment to air assist airless system because the original equipment would not work with the coating being used.

Set up quality standards that had never been in place at this facility which had been operating in the medical field for more than 20 years.

Discovered equipment to establish film builds of the coating being used. This facility had not been able to achieve this since their operations started.

Created PowerPoint documents that showed defects, good/bad standards.

Researched viscosity of coatings that had been used for over 20 years. Discovered that they had no control of this, also had never attempted any research into this.

Found recommended viscosity range recommended by supplier and demonstrated how to achieve this.

Worked on safety issues of handling this coating and process to be used.

Created work instructions for new process.

Tenneco Corp/Coatings Engineer November 2017-April 2019

Based in Kettering, Ohio, with some travel to other MFG. facilities.

I ran 3 coating lines that included an Autophoretic Coating Lines (A-coat), E-coat, and a new E-Stat coating line.

I was responsible for bringing an E-coat line that was 3.5 years old back to respectability.

Needed to replace various pumps, racking, cleaning process.

Train current Technicians on proper way to properly use equipment.

A-coat line needed new pumps and conveyor work.

The new e-stat line was installed prior to my start day.

Fixed the exhaust of acid fumes that were entering the plant.

Set up work instructions to run the electrostatic disks, along with programs for coating both solvent base coat and water base topcoat.

Set up wastewater system and trained Technicians on all procedures.

All systems used zinc phosphate and a pickling system.

Also assisted in the moving of new fabrication equipment.

CST Industries/. Director of Coating and Future MFG Technologies Oct. 2016-Oct. 2017

Based in Dekalb, Illinois with travel to two other facilities in Kansas and Tennessee.

Traveled to investigate issue in coating, forming and installation of tanks.

Their washers were 34 years old and not performing correctly which cause major issues.

I pursued new equipment and received quotes on the purchase and installation of new washers in 2 of their plants.

The third plant I received quotes on updating their spray equipment.

Researched new processes to get better adhesion on the glass coated steel tanks.

Toyota/TEMA/Engineering Specialist May 2015-Oct. 2016

Worked with TEMA which is Toyotas corporate engineering group.

Project Manager for Toyota.

Installed coating robots for various processes.

Developed a Dirt Library for defects in process.

Based in Erlanger and Georgetown, Kentucky/ Traveled to all their Auto MFG Plants.

Worked on future projects such as laser welding and metal forming.

Installed various other equipment such as large HAVC systems.

Assisted various plants on maximizing throughput and lowering DPV.

General Electric/Supplier Quality Engineering Dec.2012-May 2015

Based in Louisville, Ky, but traveled to all MFG facilities and several suppliers.

Worked with all GE divisions to improve their quality and manufacturing abilities.

Performed quality audits on suppliers.

Performed business audits on potential new suppliers.

Performed capability studies on new and current suppliers for new products.

Worked with suppliers along with internal GE companies to increase performance on stamping issues, coating issues and production issues.

Electrolux/Installation and Development Engineer March 2010-Dec. 2012

Based in Memphis, Tennessee, traveled to equipment suppliers and other Electrolux Plants.

Developed new processes for applying porcelain enamels on oven cavity.

Developed process for laser welding

Worked with potential suppliers of this multimillion-dollar coating and fabrication project.

Worked with layout and installation of equipment.

Debugged all new equipment to achieve desired goals.

Worked with contractors on construction of building.

Mubea/Coatings Manager, Chemical Engineer Jan 2007-Feb. 2010

Based in Florence, Ky, with some travel to other manufacturing locations

Developed new process for handling shot blasted stabilizer bars before coating.

Developed new process in error proofing labeling and packaging process.

Did extensive study of zinc phosphate crystal study with SEM. This study was to compare the difference in a spraying process of zinc phosphate to a dipping process of zinc phosphate.

Worked with suppliers and developed the “dual” coat process for coil springs used in top of the line auto manufacturing.

Installed state of the art powder coat systems that that would put 14-19 mils of powder on coil springs.

I had the responsibility of 3 facilities that consisted of 8 powder booths.

There are 3 separate zinc phosphate lines, 1 plant had 3 lines using the same tanks for cleaning and phosphating.

Managed waste water treatment plants in all 3 plants to insure compliance with local and federal EPA regulations.

This is a 3-shift operation in all plants, I had direct reports of a Technicians, along with shot blasting crews.

Created documents to track defects so they could be addressed.

Blackhawk Automotive Plastics/Paint Manager, Technical Advisor on plastic forming of parts.

April 1998-Dec. 2007

Based in Mason, Ohio/Traveled to other manufacturing plants in Ohio.

Tier 1 automotive supplier of “CLASS A” coated parts.

Had 4 coating lines which one was a primer only line. Two were a 2k basecoat and clearcoat line. The fourth line consisted of 1k basecoat and clearcoat on one shift. The off shift ran a depillar that had a 30gloss black applied to it.

All exterior plastic parts.

Managed directly 5 Supervisors, Paint Technicians, quality inspectors, and off shift cleaning crew. Indirect managed all loaders, unloaders and material movers.

Established new coating methods. On one product I was able to change first time quality from a 63% yield to a 97% yield on a product that we ran 15,000 pieces a shift.

Worked with plastic molding to improve their yields and get a better product for coating.

Monty Roy

6391 Browning Trail

Burlington, Ky 41005

859-***-****

adudgr@r.postjobfree.com

https://www.linkedin.com/in/.com/in/monty-roy

Contact this candidate