Manufacturing Engineer Project Management

Charles R. Jones

Clarksville, OH 513-***-**** **************@***.***

Manufacturing Engineer

A goal-oriented, high-energy Engineer with 25+ years of progressive Project Management and Engineering experience. Strong organizational and leadership skills demonstrated through the ability to successfully handle small and/or large projects requiring teams of engineers and plant personnel. Gather and disseminate information across business functions to quickly resolve production and quality concerns during product development and launch. Experience with high-budget projects greater than $1MM. Complex facilities management as well as new facilities planning and old facilities upgrades.

Product Design & Development

Project Planning & Management

Inspection of Parts / Production Machines

Thermoform Molding/Structural Foam

Holder of National Product Patents

Productivity & Efficiency Improvement

Pipe/Tube Molding

Timeline Analysis & Budget Preparation

Research & Development

Injection Molding (Decoupled)

Production Problem-Solving Skills

Blow Molding

Automotive

Training

Extrusion Training Thermoform Training Injection Training (John Bozzelli) Structural Foam Lean Manufacturing SPC ISO 9000 Molding Design Plastics Processing Unigraphics Pro-Engineer

Design FEMA Process FEMA Public Speaking Quality Management Classes

Class 100 Clean Room Dow Safety Training Injection Mold Tooling

Career Summary

Engineering Advisor/Plastic Design/Building Upgrades/Machine Maintenance (Feb 2005 – Current)

Short term projects implementing upgrades to facilities and new designs for products. Work with Engineering, Marketing, Sales and Customers to achieve the goals. Some project work for Einstein Design.

Engineering Kaivac (August 2022 – Present)

The company produces industrial grade cleaning equipment in Hamilton, Ohio.

Trouble shoot existing machines and processes (injection and Roto Molding)

Develop new Top Hat - $200K Yearly Savings (Thermoform to Injection Molding)

Develop all plastic 3-Way Valve to withstand harsh chemicals

Develop high pressure plastic injector to withstand harsh chemicals.

Re-Engineer inch Spigot. Trouble shoot to remove errors

Re-Engineer 1 inch Spigot. Trouble shoot to remove errors.

Team member to Improve First Pass Yield in Assembly (Start 40% Current 90% - 6 Months)

Mist Systems to Cool Roto Molding working area without contaminating Powder

Replace electrical cords and connections with watertight and chemical resistent

Engineering Creative Extruded (May 2019 – August 2022)

The company is a plastic Automotive parts facility in Tipp City, Ohio.

Trouble shoot existing machines and processes

New business startup opportunities

Work with newly purchased facility to start new projects and upgrade facility

Production Manager EG Industries (Aug 2018 – Nov 2018 – Short Term Improvements)

The company is a plastic injection Automotive parts facility in Circleville, Ohio.

Increased 2nd shift OEE by 16%

Decreased worker loss (people quitting) by 50%

Time Studies to increase line efficiency and work distribution

5S Projects to cleanup lines and organize. Also allowed for reduction in labor.

Change lines to pull systems rather than push systems. Lower scrap and increase Quality.

Confirm labor routings

Petmate Dir Advanced Manufacturing Engineering & Quality (Jan 2015 – Feb 2018 - Company buy out)

The company is a pet containment and supply company. Facility is injection molding from 2,100 ton to 300 ton machines, blow molding and bed filling.

Increased lbs per hour average from 200 lbs/hr to 390 lbs/hr per machine in the first year

Weight and cycle reduction in Structural Foam category, approx. $300K savings per year

Blow Molding area re-work. Average cycle from 30 seconds down to 22 seconds (4MM Parts/Year)

Added temperature and pressure control to Blow Mold cooling water supply. All molds get the same temperature and pressure. Makes the overall process repeatable, no matter which machine to tool goes into.

Overall decrease in plant wide cycle time by 4 seconds; Overall scrap decrease plant wide by 2%.

Differential venting of tooling (allowed the above improvements)

Specification and Purchase of new Blow Molding and Injection Molding equipment and utilities

Researched and implemented outside production to supplement fast growth

Researched and installed a high-tech Nitrogen system to replace the current liquid nitrogen, Yearly savings of $80k

Interviewed, hired and trained personnel that were then moved into higher positions.

Researched and acquired a 3-axis router to cut bottles instead of press and rotate cutting. Allows for non-round bottles to be incorporated into new designs, also allows non-round holes to be cut

Researched and added vacuum into blow molding, lowering pressure needed to form lettering, safety ring area and tight angles

Researched, purchased and implemented gravimetric feeders at the feed throat of the injection and structural foam machines

Researched, purchased and processed high plastification screws in the 1,000 to 1,760 ton machines

Researched and purchased (2) 500, 825 and 725 Ton (MuCell) Milacron Injection Machines; 1,000 and 1,500 Ton UBE Injection machines; 725, 1,000 and 1,900 ton Borche injection machines

Researched and purchased 3 blow molding machines

Researched Aoki blow molding system.

Purchased 26 Injection molding dies, 6 Stamping dies and 8 blow molds

Research and Purchasing included trips to venders, specifications and T1 sign offs.

Home Products Engineering Manager/QA Manager/Tool Room Manager (Sept 2012 – Jan 2015 Offered Job at Petmate)

The company is involved in storage and utility items for home, bath and garage. I am responsible for the tool room, Quality Assurance, new tooling from China and Taiwan and training process techs on the production floor. I had 8 direct reports and will pick up another 16 in the near future.

Converted a tub from 180 lb carry capacity to 300 lb capacity with small structural changes.

Reduced Tool Room expenses by training techs to do repairs we normally send out to venders

Increased efficiency numbers in production by training techs different ways of processing

Reduced Tool Room costs by teaching production floor techs less aggressive ways to process

Researched a new form of colorant to accomplish unique colors of CAMO (look for it in Canadian Tire and soon to be in Bass Pro)

Re-Design of snaps and latches to combat mis-fits and excessive scrap

Leader of the Safety Team (2012-2013). Last year had 40+ reports, this year; 16

Trips to China and Taiwan that produced successful production tools

Member of the New Product Design Team

JL Clark Project Manager (Nov 2008 – Sept 2012)

The company is involved in injection molding and steel stamping. My responsibilities included managing projects and product design. Also led customer relations and vender compliance.

Engineered new welding design for Flip & Rip (closure used for spice containers)

Designed a new part concept for Flip & Rip to utilize the new welding equipment

Lead the design team in making a Large (impact resistant) case for medical equipment

Trouble shooting for several automation and labeling lines

Design and patent for an upscale metal and plastic coffee container

Worked on award winning Green Teams

Completed classes toward my Project Management Certification

Designed, built and implemented several small upgrades to production equipment

Research into Bio-Degradable additives

Patent for Tobacco Container - #61/809,084

Huhtamaki Project Engineer (May 2004 – Nov 2008 – Company down sizing)

The company is involved in injection and extrusion molding. My main responsibilities included short and long-term projects, Customer relations and national planning and release of projects. Secondary responsibilities include problem solving for current products and building issues.

Patent for Huhtamaki involving Del-Monte and a new product offering.

M&M’s Mini Re-Design of package and closure system; induction Sealed.

Resin inventory and control for NVTC

Mold Storage and Warehouse utilization.

Bio Resin Research and implementation

In-Touch Software, Support Director/Project Director/Design/Sales, Wilmington, OH (April 2002 – Sept2003 – Company was purchased)

Investigate new technologies and Government regulations. Present customers with ideas and sales projects.

Support Director

System and Usage Analysis. This analysis established the need for two projects to increase sales and establish a new market.

Organized FAQ support for Web based support. This effectively doubled the number of customer support calls/inquires that were satisfactorily handled in a month.

Project Director

Marketing Change allowed 10% growth in sales for current markets.

Established a new market in Home Wireless that increased company monthly income by 5%.

Ongoing National Campaign to establish distributors for company produced services. Thus far the project has increased sales by 1% monthly. This remained constant through the Summer and increase to 2% monthly in the Fall.

Hancor, Inc., Project Management / Facilities Management / Product Design Engineer, Findlay, OH (Sep 2000 – Feb 2002)

Collaborated with various engineers, contract firms, assembly personnel, customers, and regulatory agencies to design, create and launch production parts; forecasted budgets and timelines; maintained production schedules and ISO Compliance records leading to successful completion of multiple projects ranging from $2K to $500K while meeting budgets and deadlines. Developments using PE and multiple rubbers (including Santoprene). Hancor comes close to a Million Dollar a Day in Sales. The primary sales are in Extruded PE pipes. Manage Facilities during project development.

Projects (Leader of Project Team, Large Teams > 10 people)

Extruded Short Length Pipe (12” ID to 30” ID). The project was accomplished in 60 days and produces a first month sales of $30,000. This specialty product also allowed bidding on $5,000,000 in projects, of which we won 35% nationally.

Design of New Couplers, 36” to 60” Able to Pass 4 Psi). This decreased the amount of returns and potential mechanical problems. The project also allowed Lower Cost Fittings Project.

Lower Cost Fittings (Design, Testing, AASHTO Certification, Marketing). This project reduced the cost of the fittings by 30% to 50%. This opened up two National Markets that we were now the lowest cost manufacturer, Storing storm water under parking lots and any application that required a medium to high number of fittings. The added sales for a month totaled $30,000.

New Gasket Designs for Extruded Water Tight in up to 60” diameter pipe (10.8 Psi). This opened up a new market that has current National Sales of $200 Million per year.

Writing Specifications for New Products

Updating Specifications and Testing for Old Products to pass ISO

Side Projects (Leader of Small Teams, < 10 people)

New Gasket Design working with Santoprene (Injection Molding). Specialty application market for high-pressure applications.

Replace Extruded Smooth Wall Pipe (3”, 4” and 6”). Project showed making small changes to our current product produced a better and more cost effective product than a more “hi-tech” re-design of the product.

Design for 3” to 6” Injection Molded Couplers. Further cost reduction and enhancement.

New Gasket Design working with Canadian supplier (Extrusion Molding). This project will allow future cost reduction and better supply lines.

Team Member

Attained and maintained ISO Certification

24” Blow Mold Re-Design

Resin Development Team

Redesigned current manufacturing dies (30” diameter to 60” diameter)

Designed New Dies for 14 plants. (In Cooperation with German Company)

Broadway Companies, Project Manager / Mold Design Engineer, Dayton, OH (Oct 1997 – May 2000)

Managed 16 – 64 Cavity Hot Runner Injection mold design projects from prototype through production phase. Responsible for design verification, research and development, quality control, and parts/production machine inspection. Developments done using PET and PEN.

50 mL preform and bottle for Alcohol

Worked with QDC and Portola for sealing cap (milk bottle)

Interfaced with multiple manufacturers to correct die problems

Acid Aldehyde reduction in bottles

Decreased Scrap from 17% to 4% on standard production

Decreased Scrap from 20% to 2% on color runs

Coordinated material supplies (Shell, Eastman and NanYa)

Research and Development (Company Patents)

Two-part injection mold (Company in Ohio); Testing of New Materials

Customer liaison to bring new products to the market

Over 300 Injection Preform Designs (Made Program that would design Preform, with standard inputs. Sales could put in variables and the preform would be available for immediate quoting)

Over 200 Bottle Designs.

United States Air Force Materials Command (Aug 1992 – Oct 1997)

Project Management / Maintain Project Costs and Time Lines

Records and Maintenance for MBE (Molecular Beam Epitaxy) Reactor

Multiple research papers on Semi-Conductors

Innovations to Machine Design; Linear Motion Ovens (Patent)

Desorption Controls for growth mechanics (Patent)

Remote operation mass spectrometer; Presentations at Local and National Conferences

Grew Crystals for lasers and guidance systems; wrote Growth Control Program for the MBE Reactor

Wright State University Instructor, Computer Science and Physics Labs

Skills

Environments: Win XP, Compaq 3000 Server, Windows 2000 Operating System

Languages: Pascal, C

CAD: Unigraphics, Solid Edge, AutoCAD, Pro-Engineer, Solid Works

PC Applications: Microsoft – Word, Excel, Project Manager, Outlook and PowerPoint

Training: Six Sigma, Plastics Flow, Plastics Design

Other: Fork Lift Training and Business Writing

Certificates: 40 hours DuPont Safety Training, Design FMEA, Process FMEA

Education

Wright State University, Dayton, OH

Bachelor of Science in Computer Engineering 1992

One year of Masters courses at Wright State

USAF Training in Physics and Chemistry

Scientific Molding – Klees and Bozzelli

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