Manufacturing Process Industrial Engineer

INDUSTRIAL MANUFACTURING PROCESS ENGINEER

CRIS SALAZAR, JR.

*************@*****.***

PROFESSIONAL SUMMARY

Previous Job Titles/Roles:

Industrial Engineer Process Engineer Manufacturing Engineer New Product Introduction Engineer

Sustaining Engineer Project Engineer RMA Engineer Integration Test Engineer

Quality Engineer Technical Writer Production Supervisor Employee/Operator Trainer Industry Experience:

Automotive Consumer Electronics Military and Defense Semi-Conductor Equipment

Aviation Electric Vehicle

Production

Marine/Oceanography Telecommunication

Aerospace Health Care/Med Device Logistics/Warehousing Energy Storage Equip Assembly Production Support Experience:

New Product Introduction (NPI) Production Line Balancing Lean: 8D, 5 Whys, 5S, Kaizen, Kanban

Perform Time-Motion Studies Cost Reductions & Waste Elimination Tools & Fixtures Implementation

First-Pass-Yield/Data Analysis Make vs. Buy & R.O.I. Analysis Productivity & Quality Improvements

Implement Ergonomic Solutions Change & Configuration Management Non-Conforming Material Dispositions

Develop Standard Work & Create

Standard Operating Procedures

Develop Production Areas, Assembly

Lines, Work Cells, Automation

Value Stream Mapping and Logistics

Develop & Track Production Area KPIs

Process Proficiencies & Duties:

Printed Circuit Board Assy (PCBA) Project & Asset Management CapEx Scope of Work & RFQ Docs

Contract Manufacturing Support Electro/Mechanical/Optical Assy BOM, PLM, Product Configuration

Root-Cause Corrective-Actions Electric Vehicle Powertrain Assy MRB, NCM & CCB Leadership Role

Hand Assy Process Optimization Plant Operations & Floor Layouts RMA & Refurbishment Operations

Develop MES Process Checkpoints Develop Equip Maintenance Plans Ultrasonic Welding

Experienced Problem Solver Functional & Integration Testing 2-Part & UV Adhesive Application PROFESSIONAL EXPERIENCE

NPI Manufacturing Process Engineer – Amber Kinetics (2022 – present) As new product introduction manufacturing process engineer, I’ve engaged hands-on by assembling numerous prototype subassemblies and final product to identify areas to improve the assembly process which included designing fixtures and tooling, procuring tools and equipment, and improving overall manufacturing flow. Presented both Powerpoint and hands-on training to warehouse staff, assembly technicians, and junior engineers, in 5S, other Lean Manufacturing concepts, and proper tool usage. KEY ACCOMPLISHMENTS:

• Hands-on participation assembling prototype products to determine proper sequence, fixture development, SOPs, etc.

• Identifying tools, equipment, tooling, and fixtures to reduce subassembly production times by 15% - 20%.

• Implementing 5S, visual workplace, Poka-Yoke, value stream mapping Lean Manufacturing techniques.

• Creating detailed standard operating procedures (SOPs), process maps, and other forms of standard work.

• Performed time-motion studies as an aid to develop standardized work; resulting in 40% production improvement.

• Actively participating in design reviews by offering manufacturability improvement ideas.

• Project leader on numerous projects which had short lead times and were critical to overall execution of prototype design.

• Collaborating with design team members, continuously laying the foundation of a manufacturing/manufacturability mindset.

• Mentoring less experienced engineers & technicians on proper tool usage, reducing safety risks, & Lean Manufacturing.

• Safety team member contributing job hazard analyses (JHA) and safety incident investigations/root causes. NPI Manufacturing Process Engineer – Zoox, Inc (2018 – 2021) Create standard operating procedures to support both in-plant and supplier manufacturing operations. Develop manufacturing sequence, along with tools, equipment, fixtures, to facilitate assembly. Train production personnel on production processes and tool/equipment usage. Communicate design for manufacturability (DFM) issues to design team for corrective action. KEY ACCOMPLISHMENTS:

• Support manufacturing of prototype lidar, camera, and imaging processing products at contract manufacturer sites.

• Support configuration management by: maintaining BOM; assembly & fabrication drawings; and ECO implementation.

• Generate manufacturing process instructions (SOPs); process mapping, and functional test flowcharts.

• Investigate production non-conformance issues: identifying root cause, then applying corrective action. Industrial Manufacturing Process Engineer – Non-Profit Food Banks (S.F. Bay Area) (2015 – 2017) Optimizing food handling & distribution processes by implementing improvements to support daily activities. KEY ACCOMPLISHMENTS:

• Perform time-motion analysis on food preparation and distribution tasks performed by volunteers and paid staff.

• Introduce lean manufacturing techniques of 5S & visual workplace to facilitate work and improve communications.

• Identify bottlenecks & eliminate waste in food movement and staging; redesigning areas for more effective space utilization.

• Identify tasks with potentially risky ergonomic motions, implementing solutions by redesigning work spaces.

• Recommend alternative methods & equipment to facilitate distribution of food to 200-300 needy families per week. Industrial Manufacturing Sustaining Engineer – Tesla Motors (2010 – 2014) Hands-on support of daily production processes related to: battery pack, electric motor, transmission, sunroof, windshield/glass installation, seating, and door panels. Project managed refurbishment of half-mile-long, 20-year-old conveyor system used to transport tire and wheel assemblies to production line point of use. Wrote request for quote (RFQ)/scope of work (SOW) for $15M of capital equipment used to assemble and install panoramic roof, windshield and rear window to support factory goal of a 500% increase in vehicle production; then project managed design and implementation of capital equipment. KEY ACCOMPLISHMENTS:

• Coordinated transfer of electric motor (Taiwan) and transmission assembly (U.S. supplier) from outside suppliers to in-house operations: designed workstations; purchased equipment/tools; developed processes; created SOPs & trained workers.

• Designed production area layout to improve cycle time 30% for battery module assembly process.

• Created over 100 technical SOP-type documents such as: work instructions; rework, repair, test, & material handling procedures; ESD controls; material non-conformance; defect identification/quality acceptance, workmanship standards.

• Received “Outstanding Achievement” award (Jan 2012) as sustaining engineer responsible for production of Toyota RAV4 drive units (electric motor, transmission, battery pack) during critical new product introduction (NPI) launch period.

• Completed numerous time-motion studies to determine cycle times, work sequences, throughput rates, and manpower requirements for assembly of battery pack, electric motor, transmission, panoramic roof, door panel, and 3rd row seat.

• Supervised 10 technicians, setting daily assignments, mentoring for career growth, writing performance reviews.

• Implemented non-conforming material areas: creating overall layout; procuring equipment (storage racks, shelves, workstations, ESD storage) and tools; defined repair and rework procedures, managed flow of materials in and out of area.

• Developed PFMEAs for powertrain components: battery modules; battery packs; electric motor; transmission.

• Spearheaded implementation of ESD controls, materials, processes, and handling methods throughout factory.

• Managed dependencies through close relationships with internal and external suppliers, insuring on-time performance.

• Created failure analysis procedure, used on every drive unit (electric motor & transmission) failing NVH/dyno testing.

• Investigated noisy transmission gear issue; resolved by implementing an improved demagnetizing and gear cleaning process.

• Redesigned panoramic roof frame subassembly production area: creating custom assembly fixtures and procuring new semi- automated tools to support production ramp from 25 to 150 units per day, a 500% improvement.

• In less than 9 weeks, transformed prototype seat assembly area to production ready, capable of supporting daily schedule.

• Successfully transferred door panel assembly from external supplier to in-house saving $200 per car. Designed U-shaped conveyor assembly line; procured tools and equipment; created work instructions; trained hourly assembly personnel.

• Provided project and capital equipment procurement leadership along with plant operation management experience. Senior Manufacturing Process Engineer – Cobham Advanced Electronic Solutions (2005 – 2010) Supported production floor activities through investigation of daily production issues and implementation of corrective actions. Participated in Kaizen, 5S, lean manufacturing, and other continuous improvement events, resulting in process improvements at all levels of production. As process documentation release chairman, improved all standard operating procedures (SOPs) through incorporation of images, drawings, flowcharts, and easy to understand text for workforce with English as a second language. In 2009, received corporate “Commitment to Excellence” award, for idea on how to engage hourly employees (subject matter experts) more effectively.

KEY ACCOMPLISHMENTS:

• Automated manual assembly processes to reduce both assembly time and labor cost.

• Chairman of process documentation release team leading compliance to “Visual Workplace”, a key company lean initiative.

• Material review board (MRB) and configuration control board (CCB) participant; dispositioned material & set configuration.

• Investigated production floor issues, resolved through implementation of tools, process, or documentation changes.

• Analyzed first-pass-yield data, identifying root cause(s), implementing corrective actions.

• Wrote over 500 engineering change orders (ECOs) to correct design, BOM structure, and other configuration issues.

• Created and maintained key performance indicator (KPI) charts & graphs for numerous production departments.

• Developed & debugged programming to support automated x-ray inspection (AXI).

• Directly contributed to company’s Lean Manufacturing initiatives by: designing mistake-proofing (Poka-Yoke) fixtures & tooling; initiating 5S improvements; value stream mapping of current & future states (process steps); participating in Kaizen & process failure mode effects analysis (PFMEA) events; creating graphics-based process and training visual aids. Manufacturing Process Sustaining Engineer – Denso Wireless Systems (2004 – 2005) Provided daily equipment operational checks including analysis of SPC data. Supported 5S and lean manufacturing efforts by auditing various factory areas and identifying issues of non-conformance. Working with software engineers, improved functional test procedure by streamlining process which led to a 15% reduction in test times. KEY ACCOMPLISHMENTS:

• Applied Lean Manufacturing strategies of 5S, Poka-Yoke, to production areas or at individual work stations.

• Optimized automated dispensing equipment to perform more efficiently, reducing cycle time and waste material by 20%.

• Developed standard operating procedures (SOPs) and tooling/fixtures for manufacturing & production assembly areas.

• Improved functional test cycle times 15%: minimizing unnecessary operator motions & deleting redundant test steps.

• Devised various solutions to difficult process operations in order to facilitate manufacture of product. Test Field Service Engineer – Vectron, Inc (2000 – 2004) Performed integration testing on automated optical inspection (AOI) equipment prior to shipment to customer. Traveled to customer sites to unpack, setup, and verify product/machine performance before release to customer. Trained customer personnel on operation of equipment, providing both classroom and hands-on training. KEY ACCOMPLISHMENTS:

• Planned, coordinated, and executed integration testing & evaluation of multiple hardware and software platforms.

• Programmed and debugged automated optical inspection (AOI) equipment to facilitate inspection at customer sites.

• Wrote detailed manufacturing and test procedures, operational standards, and quality assurance procedures.

• Traveled to customer sites performing support activities involving installation, training, and field upgrades or repairs.

• Contributed to new product releases by identifying any hardware or performance issues, and/or software bugs.

• Planned and coordinated trade show event participation by working with internal/external vendors to coordinate logistics. EDUCATION

• B.S. Industrial Technology, San Jose State University, San Jose CA

• A.S. Natural Science, Ohlone College, Fremont CA

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