Senior Manufacturing Engineer - Process Improvement Leader
Resume:
Daniel Blubaugh
Senior Manufacturing Engineer
Plainfield IL 60586
******.*.********@*****.***
OBJECTIVE
To lead a diverse manufacturing team in driving process improvement, waste elimination, and strategic implementation initiatives that enhance productivity and efficiency. Leverage existing technical expertise and project management experience while continuing to expand knowledge across multiple manufacturing disciplines and further refine leadership capabilities to achieve operational excellence.
EDUCATION —
EXPERIENCE
MASTER of SCIENCE
Northern Illinois University
Industrial Management and Technology
2021-2023
GPA 3.94
BACHELOR of SCIENCE
Northern Illinois University
Applied Manufacturing Technology
2019-2020
GPA 3.96
ASSOCIATES of SCIENCE
College of DuPage
Manufacturing Engineering 2017-18
G.P.A. 3.845
ILLINOIS MANUFACTURING FOUNDATION
2015-2017
KEY SKILLS—
Machinist Certification
Solid Cam
CMM/3d-scanning
Python/PLC
CBN
Machine Learning
AMR
Root Cause Analysis,
Machining application analysis,
Process Improvement,
Powdered metal machining,
PPG Programming
Cell Design
FDM Printing; SLA Printing
BURGESS NORTON – AMSTED AUTO GROUP – Geneva, IL
Senior Manufacturing Engineer 2023–Present
Lead Cap-Ex projects, departmental financials, and continuous improvement initiatives across machining and secondary operations, driving cost reduction, process optimization, and automation to enhance throughput, quality, and profitability.
Key Achievements:
Managed financial performance and capital projects from concept through completion, ensuring alignment with cost, quality, and delivery objectives.
Reduced annual insert spend from $770K to $598K through process optimization and Power BI–based consumables tracking.
Delivered $638K annual savings on a $78K investment by implementing line balancing and automation for Honda machining, achieving 34% cost reduction, 22% throughput gain, and full measurement automation.
Led cross-functional team to design and integrate an automated inspection and loading cell with custom conveyors for BorgWarner/Toyota, eliminating setups and six labor positions, saving $535K annually on a $132K investment.
Implemented an in-house automated flex line, reducing four operators and generating $2.4M annual margin improvement with an 11-month ROI.
Enhanced CNC machining programs to increase throughput and tool life; resolved challenges with powdered metals, heat-treated steels, and CBN tooling.
Championed Continuous Improvement (CI), RCA, and waste elimination initiatives through collaboration with operations, quality, and engineering teams.
GKN WALTERSCHEID OFF-HIGHWAY SYSTEMS – Woodridge, IL
Machining Supervisor 2016-2018 Manufacturing Engineer 2019–2023
Managed 14 machinists across multiple shifts, directing workflow, resolving machining and broaching quality issues, and ensuring production efficiency and uptime.
Manufacturing Engineer 2016–2019
Led Cap-Ex project teams delivering automation, process improvement, and data-driven solutions in machining and assembly operations.
Key Achievements:
Directed projects in autonomous material handling, assembly automation, machine learning (TensorFlow) for visual inspection, and a multistage chemical wash and automated epoxy paint line.
Developed and implemented operator training, standard work, and continuous improvement documentation (A3s, RCA, PDCA, and KASS).
Conducted time studies and TACT calculations using foreign element analysis to identify bottlenecks and optimize flow.
Designed and managed durable tooling systems (broaches, fixtures) and implemented tracking programs to minimize downtime and extend tool life.
Engineered and modified manufacturing cells and plant layouts to increase capacity and improve material flow.
Designed, validated, and troubleshot fixtures for broaching, assembly press, coating, heat treat, and torque testing systems.
Established a tool sharpening and management program to improve utilization and reduce tool-related downtime.
EON PROPERTY MAINTENANCE – Chicago, IL
Owner / Operator 2010–2015
Owned and operated a property maintenance business serving condominium complexes, apartment communities, and hotels.
Key Achievements:
Managed day-to-day operations, accounting, billing, and payroll for contracts exceeding $500K annually.
Supervised a team of two employees, ensuring timely and quality service delivery.
Oversaw client relations, budgeting, and operational logistics to maintain consistent profitability.
Certification
APPLICATION
Project Management Professional
FEMA CERT #s IS-00005, IS-00230d, IS-00235c, IS-00394a
Technical Writing
Process Improvement
Lean implementation
Six Sigma Green Belt
Certified Solid Works Associate (CSWA)
Implemented process and automation improvements across multiple machining operations, delivering significant productivity gains and cost reductions. Key highlights include:
Machining Cell Optimization: Increased production output by 25%, reduced tool consumption, and eliminated manual labor through flow redesign and UR-10 camera-guided automation, achieving $624,350 annual savings with a 3-month ROI.
Cost Reductions: Lowered insert costs by $71,000, brush deburring by $28,000, and durable tooling costs by $12,000 per month through testing, process changes, and tooling optimization.
Data-Driven Improvements: Developed Power BI dashboards for plantwide tracking of tool life, KPIs, and production metrics, improving visibility and decision-making.
Throughput Increases: Achieved a 37% throughput improvement on clutch cells through time study analysis and layout redesign, cutting production costs by $375,000 annually.
Automation Integration: Led North America’s first integration of an Omron HD1500 AMR, automating raw material delivery and reducing staffing in parts picking by 42%.
Training and Continuous Improvement: Established a machinist training program and drove ongoing cycle time reductions and waste elimination initiatives across operations.
LEADERSHIP
Guest lecturer For Robotics and Electronics classes
East Aurora High School.
Small business owner
Managed fourteen machinists.
Managed three people on CAP-EX Projects with total annual improvement expenditures of $2 million.
Currently Manage 5 setup machinists, and various teams on CAP-EX Projects with total annual improvement expenditures of $3.5 million last year.
REFERENCES
Luis Garcia (Illinois Manufacturing Foundation Program Director): 815-***-****
Chris Wetzel (Former Professor): 708-***-****
Kirk Jones (Co-Worker): 331-***-****
Bruce Tassone (Former Boss): 815-***-****
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