Maintenance Manager Engineering

JOHN D. WHITE

.

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

***** **** **. ******, ** 48042

http://www.linkedin.com/in/jwhitemich

248-***-****(m)

MANUFACTURING ENGINEERING / MAINTENANCE MANAGER

SUMMARY

yrs. Sr. Manufacturing Consultant -Tata Consultancy Services

10 yrs. Engineering Manager (Process, Facilities, Tooling and Skilled Maintenance) - Dana, IPG, JCI, Forvia

14 yrs. Throughput Improvement, Manufacturing Excellence Team Leader - General Motors

3 yrs. Maintenance General Supervisor – Skilled Trades - General Motors

8 yrs. Project Management – General Motors, Dana, TATA.

BSEE Kettering University

Inspirational and passionate leader / teacher with mentoring skills. Quick to identify factors CTQ and profitability sinkholes. Able to communicate critical details and transfer technical knowledge to others quickly and accurately. Skilled at devising automated and manual data collection systems and pertinent DOE’s for making relevant improvement decisions with stakeholders. Always collaborate with team on priority decisions so we can apply resources with understanding and focus.

Cross-functional knowledge of entire automobile, light & medium duty truck manufacturing process which was obtained by leading throughput improvement projects in over 30 assembly and manufacturing plants throughout North America -- Body, Paint, G/A (Trim & Chassis) as well as metal fab, powertrain, and component plants.

High technical and mechanical aptitude: Hands-on with skilled trades, IT, SMEs, production teams, and plant operations management. Able to teach essential manufacturing concepts in a practical manner - physical science, electrical, mechanical, mechanics, heat transfer, HVAC, P&ID, GD&T Gage R&R, etc.

Substantial experience maintaining production systems, process equipment & physical plant in production environment. Electrical Engineering background; experienced in high automation - PLCs, MMIs, robots, plant floor IT systems. Plant facilities engineering - HVAC, primary power, fire protection, nitrogen generation, waste treatment, RTOs, water towers.

Strong knowledge of continuous improvement, TOC, TPS, WCO, Lean Six Sigma (certified Green & trained Black Belt), value stream mapping, profitability analysis, (using lean accounting methodology), visual management.

Accomplished at optimizing complex automotive manufacturing systems. Expert in configuring and using math-based tools - discrete event simulations, robot simulations, takt time data, data collection systems (SCADA, MES) and throughput analysis to direct process improvements.

Continually focused and attentive to employee safety, OSHA and environmental regulation compliance. Plant commissioning experience.

PROFESSIONAL EXPERIENCE

Kohls Consulting at Dexter Axle (Elkhart, Indiana and Albion, Indiana)

Senior Manufacturing Consultant – (Independent Contractor) Throughput improvement consulting (Dec 2022-Mar 2023)

FORVIA (Faurecia) SAS Interior Modules (Sterling Heights, MI) – Assembled RAM truck instrument panel and complete dash for just-in-time delivery to SHAP

Engineering & Maintenance Manager (May 2022 – Sept 2022)

Managed Engineering and Maintenance department. Resolved bottlenecks, led new automation projects, assessed production equipment for updates and repairs, planned downtime work. Mentored and coached tea

NDX Human Capital Solutions (Rochester, MI) – (contract house)

Maintenance Specialist (Contract job - Mar 2021 thru Feb 2022)

Contracted to GM Lifecycle Cost Group to create and verify MAXIMO PM system Job Plans for FZ Hamtramck Paint Shop.

TATA CONSULTANCY SERVICES (Mumbai, India) – Multinational consulting company specializing in technology driven modernization and IT systems/maintenance. TCS has 149 locations in 46 countries.

Sr. Manufacturing Business Consultant (Troy, MI - 2017 to Dec 2019)

Recruited into Innovation and Transformation Group to lead plant floor implementations during delivery of IT projects such as MES and MOM systems and other technology driven improvements to client’s manufacturing systems.

Organized diverse (distributed on-shore/off-shore) teams to deliver strategy documents and presentations including proposals, system designs, SOWs, POVs, POCs, and Industry 4.0 transformation roadmaps.

Delivered exceptional results on client’s MES product selection and functional specification project. Gratified client with ideation for new throughput improvement and predictive maintenance projects and a new PLC program change management tracking system (no cost to TCS)

Produced multiple IIOT assessments for client projects emphasizing manageable tranches for ROI.

Developed QMS system for client’s ultra-sonic weld process that used predictive analytics on streaming data from multiple machines. (Predict which machines were trending to produce bad parts, signal tool changes, etc.)

DANA POWER TECHNOLOGIES (Maumee, OH) – Global supplier of automotive power delivery systems and components – including axles, drive shafts, transmissions, cooling systems and more.

Manufacturing Engineering Manager (St Clair, MI- 2014 – 2016)

Restored dignity and respect for Maintenance and Die Repair Technicians by providing competent leadership and sheer determination to thoroughly detail and explain functional accomplishments to staff. Within three months of starting produced a flawless January 2015 launch of all plant assets for the first time at St. Clair after any extended shut down. All subsequent cold start-ups have been flawless.

Created the “Maintenance Coordinator” role which removed clerical duties, part procurement, PM scheduling from Process Engineers - providing the necessary resources and engineering team leaders for a serious continuous improvement culture.

Developed Dana’s new generation of stacked dish cooler automated assembly equipment that doubles throughput on each line. The design moves the bottleneck, reduces scrap, and has several new upfront error proofing features built in. It incorporates Fanuc M-2 iA Delta Robots, line tracking machine vision, and flexible tooling for fast changeovers, and has the ability to run with one or more robots down. (This is my signature accomplishment at Dana.)

Implemented multiple high - value QWL (quality of work-life) plant floor projects including new plant floor air conditioning with a very innovative design for duct work and air flow control which has become the best in class for all Dana brazing plants. Other QWL projects include a showcase kitchen design, designed and constructed on my personal time off-shift, based on the Dana diamond theme and colors. (This is another signature project due to unique design, materials and construction.)

Met MRO financial goals & delivered over 5M in capital projects on-time with-in budget

INTERTAPE POLYMER GROUP (Montreal, Quebec and Sarasota, FL) – North American and European manufacturer of tape and

packaging projects. Second largest producer of tape products in North America.

Engineering Manager, Innovation & Technology Manager Marysville, Mi 2012 – 2014

Chief engineering executive within the site. Managed process and facilities engineers and Maintenance Department.

Rebuilt depleted process capabilities and put facility on the road to a WCO

Corrected compliance issues, implemented widespread functional and ambient workplace improvements.

GENERAL MOTORS (Detroit, MI) – Consulting Engineer 1994-2011 based

(Based at GM Technical Center, Warren, MI)

1994- 2011

Lead Project Manager – Over 40 GM sites - US, Mexico, Canada – Assembly, Metal Fab, Powertrain, Components

Project Management - Led system installations in program launches - last was Fairfax 353/354 (2010 Buick LaCrosse). - Led engineering teams of four (4) to 12 team members at remote plants (controls engineers)

Process Improvement - Implemented PLC & MES based data collection systems to automatically collect, analyze, and report data for continuous throughput improvement programs in existing high demand plants throughout North America.

-Led process engineering, production teams, and skilled trades in planning and implementing improvement projects.

Process Engineering - Sub-contracted for operational review of all new paint process & facilities for 2012 Chevy Sonic Paint Shop commissioning (Orion Assembly, Orion MI) with goal of achieving highest First Time Quality rate.

See Addendum “General Motors Experience”, GM Plant Assignments (dtd 10.25.19)

JOHNSON CONTROLS, INC., WOODBRIGE FOAM CORPORATION

1991 - 1994

Plant Engineer / Maintenance Superintendent (foam seating) Whitmore Lake, Mi 1991 - 1994

Whitmore Lake, MI

Directed Engineering and Maintenance& Tooling Department of six (6) salaried and 24 hourly. Planned all project work and assigned daily activities. Continually improved throughput and workplace environment.

Saved $50K/month - designed new mold release mix, pumping and delivery system and new hydraulic control system on mix heads eliminating leak failures. Installed annunciator & maintenance call systems improving MTTR and eliminating $12K/month of scrap.

Meticulously refurbished a rundown facility, remedying years of neglect, enabling JCI to sell it to Woodbridge Corporation.

GENERAL MOTORS

General Supervisor – Maintenance Skilled Trades 1973 - 1987

GENERAL MOTORS BOC ORION ASSEMBLY, Orion, MI, and GMAD Lordstown, Lordstown, OH

Responsible for running Maintenance Department during production for Body Shop, Paint, and General Assembly. Managed resources for daily and downtime maintenance activities and supervised construction projects. Planned downtime construction activities with Engineering, Production, Union, and outside Contractors. Engineered and implemented many mechanical and electrical equipment improvements which solved dozens of production quality, downtime, and throughput problems.

Promotions: Senior Plant Engineer, Senior Systems Analyst, Electrical Engineer, Jr. Elec. Engr.

Started as GMI co-op student at GENERAL MOTORS ASSEMBLY DIVISION Lordstown, OH.

Transferred to new Orion plant in January 1982 as Senior Systems Analyst to lead installation of plant floor IT systems.

Attendance record: Three (3) lost workdays in over 14 years of service.

TECHNICAL, ENGINEERING, MAINTENANCE & PROJECT EXPERIENCE

(Professional Knowledge Base - addendum to resume)

PROCESS AND QUALITY IMPROVEMENT / CONTINUOUS IMPROVEMENT STRATEGIES AND METHODS:

Deming (PDCA), Goldratt (TOC) & Bottleneck Analysis, TQM, 5S, Lean (TPS), TPM, SPC, SMED, FTQ, Value Stream Mapping, Visual Management, Lean Six Sigma (certified Green Belt), automated data collection systems. Simulation.

COMPUTER SKILLS & DATA COMMUNICATION: Office, Visio, some Project & some AutoCAD. IEEE Interface standards, CATV & broadband. TCP/IP networks, switches, segmenting, V-LANs. Industrial Ethernet, field bus networks.

PLANT FLOOR IT SYSTEMS: Enterprise level production monitoring, supervisory control & data acquisition systems for manufacturing and assembly plants (SCADA & MES), Energy Management, Facilities Monitoring and Control, Fastening Monitoring and Control, Vehicle Function Test, Component Verification, ANDON, Error Proofing, Routing and Tracking, build sequence broadcast, Emissions Test, Vehicle Alignment, Roll Test, etc. MDT MASS. Real time data driven Throughput and Process Improvement Systems using SPC and simulation. Experience commissioning Wonderware & Cimplicity, MAXIMO.

CONSTRUCTION & REPAIRS: Personally proficient with test equipment, hand tools, power tools, welders, paint application equipment, metal cutting machines, and material handling equipment used in industrial and construction trades. Having learned these skills over time on various construction and mechanical projects is helpful in developing a trusting relationship with all skilled trades (Elec, M/W, P/F, etc.) Able to establish realistic schedules and assure quality workmanship.

PREVENTIVE MAINTENANCE: Maintenance procedures, PM programs, CMMS, visual management controls. Lubrication programs, central lube systems. Investigating cost benefits/risks of outsourcing specific technical tasks and focusing on core competency of front-line maintenance. Integrating lessons learned into cost-effective sustainable PM solutions.

MECHANICAL HANDLING EQUIPMENT: Conveyors and controls (monorails, P&F, COE, IP&F, AEM, AGV’s, skid systems, skillets, etc.). Loaders, transfers, hydraulic & pneumatic systems, lifts, elevators, lowerators, turntables, gantries, WIP storage systems, lean configurations. 6 and 7 axis robot configurations.

CONTROLS: Relay logic, Allen Bradley PLC 5’s and Logix 5000’s. Safety relays. Fanuc Robots. GM CCS-2 & CCH-1

WELDING and BRAZING: Robotic spot, MIG, plasma, stud, and laser welder maintenance & repair, geo-set, welding fixtures, sealer systems, hemmers, automated laser, optical, and robotic inspection systems. FLUX-LESS ALUMINIUM BRAZING.

PAINT PROCESS SYSTEMS: Paint spray booths, clean rooms, air filtration, pre-treat, phosphate, and ELPO systems. Batch and on-line mixing systems. Solvent recovery. Pumping, circulating, heat transfer systems. Automated and robotic paint application systems, using conventional, electrostatic, bells & turbines, HVLP, and airless technologies. Spray booth air balance, over-spray elimination and sludge handling. Oven, incinerator, RTO operation. Booth, oven, conveyor, equipment cleaning, and water, dry ice, soda blasting. Personal experience using lacquer, enamels, epoxy, urethanes, and compatible and effective solvents. Personally capable of using siphon, pressure, airless, HVLP guns. (Completed many custom paint jobs - cars, boats, houses) Familiar with VOC material compliance, air, liquid, solid waste discharge and disposal requirements, EPA and MDEQ application and permit requirements, knowledgeable in spill prevention and containment requirements.

URETHANE FOAM PROCESSING: Handling isocyanate, high & low pressure mixing systems and dispensing heads, mold maintenance, environmental concerns. Foam finishing and repair process. Foam formulations for dual density, etc. Solvent and water-based release agents.

PLANT FACILITY MAINTENANCE: Primary power, substations, high voltage switchgear, building electrical maintenance, and lighting. Powerhouse, chillers, cooling towers, large synchronous motors, large compressors, waste treatment, DI water generation. HVAC, energy management, fire protection and security, time and attendance systems. Computer rooms, high and low voltage cabling systems. Power factor correction, cathodic protection. NFPA, NEC, OSHA, MIOSHA, EPA, MDEQ.

ADHESIVE TAPE MANUFACTURING: Solvent-based adhesive manufacturing using natural and synthetic rubber. Web coating, solvent recovery, curing. Converting material into wholesale and retail products. Factors CTQ, EH&S considerations.

FINANCIAL: Financial knowledge, business accounting principles, SOX. Profitability analysis and Lean accounting principles. Attentive to world financial markets (currency, debt & equity markets, commodities and derivatives).

OTHER SKILLS AND INTERESTS: Private pilot, auto mechanics, construction projects.

CONTINUING EDUCATION INITIATIVES: Completed Lean Six Sigma Black Belt course instruction, passed exam (project deferred). Completed PMP course instruction. Completed CompTIA Network Plus, & ITIL v3 r2011 courses.

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