Process/Manufacturing Engineer

CECIL SMITH

**** ******** ***** ***** **** OH ***23 Mobil: 937-***-****

Home : 614-***-**** ***********@*********.***

Engineering Profile

Detailed-driven Process/Manufacturing Engineer with over 15 years experience in maintenance, 7 years experience with controls, a journeymen electrician, and a track record of success in consistent achievements of engineering project goals. Skilled problem identifier and troubleshooter able to pinpoint and resolve issues in early stages to avoid cost / time expenditures. Efficient, organized leader with success in coordinating efforts within internal-external teams to reach and surpass expectations. Expert-level skills in manufacturing, equipment reliability, and process engineering; to include development and implementation of quality control testing and documentation in compliance with TS-16949.

Core Competencies:

 Lean Manufacturing Concepts

 Process Failure Modes and Effects Analysis

 Design Failure Modes and Effects Analysis

 Maintenance Management

 Root Cause and Effects Analysis

 Experimental Design Activities

 Team Training & Mentoring

 Project Management

 Statistical Process Control

 Quality Assurance Standards

 Engineering Documentation

 Thermoforming Process

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PROFESSIONAL EXPERIENCE

Visteon Corporation – Springfield, OH Mar 2009 - Present

Process Engineer IV, Lead Manufacturing Engineer

Scheduling of plant production for the manufacturing of Chevy Cobalt fuel tanks and the manufacturing of Ford canister vent valves to include; managing a team of skilled tradesmen and scheduling/coordinating equipment repairs and preventative maintenance to all plant equipment. Managing a team of engineers and production supervisors to achieve weekly build targets and equipment OEE targets, including: strategic placement of key employees, optimization of product flow through the system, and coordination of employee involved production optimization teams. Key Accomplishments:

 Instrumental in developing a lean culture in plant employees through the implementation of lean manufacturing philosophies and concepts; 5S Workplace Organization, Kaizan, Andon Boards, Gemba Walks, Total Productive Maintenance, Standardized Work, Value Stream Development, Continuous Improvements, JIT and Kanban systems.

 Reduced canister vent valve assembly scrap rate by 37% through equipment and plc programming improvements.

 Reduced non-prod inventory by 31% by eliminating non-critical equipment parts on the basis of short lead times as a cost save.

 Responsible for fuel tank thermoforming and canister vent valve manufacturing to include:

 Developing product/process flow through value stream mapping

 Evaluating and modifying Control Plans and submitting to customer for approval.

 Evaluating and modifying product PFMEAs

 Managing equipment acquisitions and installation

 Conducting DOEs for product/process improvements

 Providing feasibility studies for engineering change request

 Conducting capability studies to process and equipment to determine product stability

 Using SPC daily to monitor product quality and process consistency

 Guiding bi-monthly reviews of the PFMEA to include: review of high RPN issues, to add any new issues and to verify previous changes were still effective and accurate.

 Developing/implementing procedures to include training plans, visual aids and inspection criteria for employees to ensure the products have no defects and meet customer quality standards.

 Highly skilled in high density polyethylene twin sheet thermoforming.

Visteon Corporation – Springfield, OH Oct 2005 – Mar 2009

Process Engineer III, Equipment Reliability & Maintenance Engineer

Managing a team of supervisors and skilled tradesmen, responsible for PM planning and completion (currently achieving 95% on-time completion), project planning and completion, and equipment changeover support, all geared toward the reduction of equipment downtime and increased OEE. Key Accomplishments:

 Key member in launching automotive fuel tank manufacturing process for Chevy Cobalt and Saturn Ion as Lead Engineer for thermoforming process.

 As Lead Engineer, acquired and launched the following equipment from a facility that was closed down: Canister Vent Valve Assembly line and Coil Winding Machine. (Through machine improvements, process flow improvements, and implementing other lean manufacturing practices, was able to reduce the original required number of operators by 50% and still meet customer requirements as a cost save.)

 Responsible for facility equipment, equipment maintenance and equipment reliability to include:

 Maintaining and updating web based preventative maintenance management system, Maximo

 Coordinating all equipment repair and maintenance activities

 Coordinating with outside contractors and vendors for equipment repairs when needed

 Coordinating facilities routine maintenance with outside contractors

 Ordering required parts and materials for PMs, CMs, and EMs.

 Inspecting worked performed by technicians for completeness

 Managing equipment acquisitions and installation

 Reduced thermoforming startup scrap cost by 56% by optimizing the thermoforming start up process and allowing the machine to stabilize quicker, reducing the number of parts scrapped during startup.

 Maintaining and modifying PLC systems, to include: Micrologix 1000, 1100, 5000, PLC 5, and SLC 500.

 Making program changes and maintaining series IRB 6600 ABB robots and sc4 plus controllers.

Visteon Corporation – Chesapeake, VA Jan 2004 – Oct 2005

Lead Production Supervisor

Supervising a team of production supervisors to include; developing practices to achieve daily build targets and equipment OEE targets. Responsible for developing production supervisors’ standardized work, coordinating scheduled equipment downtime with engineers for preventative maintenance, and assisting in the development of standard operating procedures. Key Accomplishments:

 Managed a team of 2 shift supervisors, 18 technicians, and 42 production associates.

 Functioned as a member of a team that reduced overall mold change time from 8 hours to 3.5 hours.

 Coordinated between 3 shifts to ensure engineering equipment projects/improvements were completed on time.

 Identified process variables and implemented corrective actions to increase line effectiveness

Visteon Corporation – Chesapeake, VA Aug 2003 – Jan 2004

Production Supervisor

In charge of a team of 16 hourly production associates in the thermoforming and assembly process in the manufacture of fuel tanks. Ensured all were properly trained and documented all personnel matters to include scheduling, discipline, and training requirements. Assisted the Human Resource Department with union grievances. Key Highlights:

 Managed a team of 6 maintenance technicians, responsible for completing PMs in accordance with the PM schedules.

 Recognized and implemented actions to contain and correct product deviations to protect the customer.

 Assisted in development of a maintenance history-tracking database. Achieved a “0” PPM rating and 100% delivery rating.

Visteon Corporation – Chesapeake, VA Mar 2003 – Aug 2003

Maintenance Technician

Maintained, repaired and installed various types of electronic equipment and related devices such as industrial measuring and controlling equipment, Programmable Logic Controls, industrial robotic devices (ABB and Fanuc Robots), programming, and logic.

Key Highlights:

 Applying technical knowledge of electronic principles in determining equipment malfunctions, and applying skill in restoring equipment operations.

 Inspecting, diagnosing, maintaining and repairing various types of machinery, such as motors, pumps, conveyor belts, fans, etc.

 Regularly performing preventative maintenance on all electrical and mechanical equipment.

 Personally compiled parts list, ordered parts, installed and wired 4 – 480v 400amp panel disconnects to feed plant compressors and air dryers for a cost save of $35000 to the company by not having to hire contractors to install.

International Brotherhood of Electrical Workers – Norfolk, VA Jun 1995 – Mar 2003

Journeyman Electrician

Installed and wired several different types of electrical devices as well as being assigned job foreman on several different projects to ensure a timely completion of job assignments and that quality and safety standards were adhered to at all times.

Key Highlights:

 Installed and wired 4 linear thermoformers at Visteon Chesapeake Plant for the manufacturing of 2003-2004 Ford F-150 pickup trucks fuel tanks.

 Managed a team of 16 workers at Norfolk Ford Plant for 2004 Ford Pickup Truck assembly line installation.

 Managed a team of 23 workers at building U-80 Norfolk Naval Base for upgrades and renovations

 Installed and wired motors, transformers, switchgear, buss ducts, control panels, programmable logic controllers, etc

USS Emory S Land (United States Navy) – Norfolk, VA Feb 1989 – Mar 1995

Interior Communications Electrician

Repaired and maintained shipboard communication system. Also repaired motors, switchgear, variable frequency drives and other electrical shipboard equipment.

 Prepared and interpreted blueprints, wiring diagrams and sketches for electrical communication equipment

 Maintained plotters and dead reckoning equipment

 Maintained and repaired shipboard navigation equipment.

EDUCATION/TRAINING _

Columbus State Community College – in progress

NJATC/IBEW Union Electrical Apprenticeship (5yrs)

 State Licensed Journeyman Electrician

Interior Communications Electrician A School (US Navy) 22wks

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