Versed, experienced welding/manufacturing/robotic engineer

Resume for

JAMES E. HARROD

**** ****** **. ****** *****, Indiana 47119

(H)812-***-**** (Cell)765-***-**** email: ************@***.***

Career Summary

Highly skilled mechanical/welding engineer with more than 15 years of progressive responsibility and expertise in national and international heavy industrial and manufacturing arenas. Responsible for all phases of process development (cradle to grave concept) including design, installation and automation of productions systems. Knowledge of Robotics, Some PLC’s, QS9000 standards, ergonomics and safety parameters. Skilled in budgets, training personnel, inventory control and acquisition, and plant maintenance.

Technology Summary

• General – MS Office, MS Word, MS Powerpoint, MS Excel, MS Project, MS Access, Wordperfect., MS Works

• CADD – AutoCad, AutoCad Lite, Vis Veiw.

• Man-Machine Interface (MMI) – Gallil, Standard XYZ programs. (PA,PR instructions)

• Lasers – Coherent, Lumonics, Synrad, Photon.

• Various power supplies/ controllers- MIG, TIG, Plasma, and Resistive Welding

• Motoman/Fanuc Robotic programming, Some ABB

Professional Experience

MST/ Harley – Davidson (Pa.) 2008-2009 Manufacturing Engineer

Production Support- 2nd shift Engineer/Supervisor for redesigned touring frames, robot to robot welding.

Work with setup, maintenance, production personnel to correct/improve welding/ productively issues.

Reduction in Workforce – Contract Position

Accomplishments:

Reduction of weld repairs by 20%

Dana Corporation- Structural Solutions Group (Ky) 2005-2008

Manufacturing Engineer

Launch new products for six production facilities. High production welding. 90% automation. From concept to production of light truck frames. Leading plant engineering for assigned tasks. Ford ,General Motors, and Toyota Platforms.

Accomplishments:

Moving of supplier production cells after supplier went bankrupt while maintaining production is a month timeframe.

Took a 30 frame per production line to 52 frame per hour(90 welding and 7 material handling robots)

Team member with Toyota Trundra/ Sequoia new product launch

Assisted with change over of .052” Mig wire to .040” mig wire- reduction of repairs by 20%

Lead Engineer for New Tacoma Shipping Frame Rack Conveyor System.

Team member for Tacoma Frame ECI for new models.

Aerotek/Tenneco (Tn) 2004-2005

Welding/Senior Process Engineer

New Product Launch, improving productively, Customer concerns, Floor support, existing lines improvements, Training. Scrap reduction, Improve quality.

Accomplishmnts:

Reduced a long term weld spatter concern by developing pulse weld parameters

Increased consistent productively by 30% thus meeting shipments with a reduction of overtime 40%

Improved robotic programming ease of operation.

Improved Components gauges for consistent production.

Faurecia Exhaust (Ky) 2002-2004

Welding/ Senior Process Engineer

Automatic welding cells- robotic and rotary. Manual welders qualifying. Gauging. Development of new processes. Fixture redesign, modifications. ECO’s, PPAPS, Production Launch, Productively refinement, Scrap reduction, BOM generation and verification, Operator /setup instruction. Work with components cells to reduce gaps and help provide an consistent presentation to automatic welding.

Accomplishments:

Increased productively of final assembly 30%, reduced scrap by 20%

Inoperative Robotic weld cells to productive in three months- four cells

Developed a welder qualification program

Increased plant knowledge of automatic welding

JEH Consulting (Ill) 2002-2002

Owner/Manufacturing/Welding Engineer

Programming new production robotic cells. Material handling, resistive, MIG, Plasma, Laser, Dispensing, and water jet cutting. Hands on. Some fabrication and tooling improvements. Some repair of power supplies, robots, and cabling. Using design of experiments define a tolerance parallelogram / range of parameters for welding. Assist with updating FMEA’s,CPK’s, and quality plans. Suggest error proofing devices and practices. Some ladder logic modifications and interfacing. Cad Drawings updating.

Accomplishments:

For a 10 million dollar project was contracted to program loading and unloading robots in conjunction with a gantry/laser system in real time part identification. Company has orders for four more systems.

Motoman Robotics(OH) 2000-2002

Advanced Systems Technician – Welding/Material Handling

Programming and interfacing of robotic production cells. Installation of cells at the customer site. Managing budgets, hours, and customers. Training of personnel with different techniques for educational levels. Welding (MIG, Plasma, Laser, and Resistive), cutting (Water jet, Laser, Plasma, Flame), dispensing (sealant, adhesives), and material handling (Press brake, Laser cutting, Die tendering) applications. Tooling improvements. Develop the welding process and parameters. Suggest error proofing devices (Poka-yoke).Ensuring all documentation is updated and correct (PFMEA’s, schematics, BOM’s, and drawings). Calculate CPK’s. Designation key control characteristics/ key process characteristics (KCC/KPC’s). Destructive testing of welds to ensure a good weld is being produced. Evaluation of process by visual and or gauges, monitoring devices- heat management, metallurgical concerns, and gage requirements. Modifications of ladder logic.

Accomplishments:

Took a high risk welding application of resistive spot welding 4130 HSLA to Galvoneal. Using design of experiments in conjunction with destructive testing found the optimized range of parameters for consistent production to meet Mil Standard requirements of passing salt fog, indentation, and fatigue test. The cell meant cycle time requirements and was under budget by 10%. With this cell was a 2nd dispensing robot that had to be programmed in the field. Meant projected project hours for install and debugging. This was a multi tooled cell for four parts with ten variations. The welds meant MIL Standard criteria the first attempt certification by Customer.

Performed all programming and interfacing at a Customer site of three robotic MIG welding cells. High production rates with a new introduced welding power supplies. All three cells that had two robots per cell as running production in 1.5 weeks. The project was under hours by 10%. The Customer received their contract for 2 million dollars.

Continental Design / Delphi Energy Batteries, Div. Of General Motors, (IN) 1999-2000

Manufacturing Engineer

Incorporated over 40 equipment changes for lean production cell, meeting Takt time and decreasing cycle time to meet production requirements. Documentation of QS 9000 standards. Establish boundary limit criteria. Trained other engineers, operators and maintenance personnel. Maintained budgets by tracking hours, time lines, additional expenditures. Supervised twenty contract personnel and skilled tradesmen. 80% travel

Accomplishments:

Tasked to virtually be the clean up crew to debug the twelve final assembly lean production cells. The twelve cells consisted of nine machines tied into a cell with interfacing. With a team effort of documenting major show stoppers and possible solutions started to improve the robustness and productively of cells. This ranged from floor improvements, conveyer belt changes, changing sequencing of operations, waste management, creating boundary examples, tooling redesign, and training of operators, maintenance and plant engineering. Three out of four plants had accepted the lines with meeting the requirements of 1500 lead acid batteries per eight hour shift. Reliability was increased by 20% and rejects were reduced by 10% with a continuing improvement program. Thus savings of one million for a year.

Rapid Design / MidWest Stamping (OH) 1998-1999

Welding Manufacturing Engineer

Responsible for new product launch, managing, debugging, and production. Improving processes and reducing scrap. Very heavy into MIG and resistive welding. Incorporated Poke yoke devices and other error proofing techniques. Improved tooling to maintain gage and functionality. Trained operators on welding processes. Root cause analysis.

Accomplishments:

Implemental with the restoration of the Ford Q1 supplier designation by reducing scrap by 30%, increasing production by20% while increasing quality by 50%. With feasibility studies and design of experiments with documentation proved out the process and assemblies. In a six month time frame.

Trained Quality personnel in regards to gauge interpretation thus reducing scrap by 30%.

Continental Design/ Delphi Automotive, Div. Of General Motors (IN) 1995-1998

Manufacturing Engineer / Welding Engineer

High-volume automotive production. .Shainin Journeymen. Resistance, Ultrasonic, SMAW, GTAW, GMAW, PLAW, and laser welders, in national and international plants. New product launch- new equipment and high volume production lines. Performed troubleshooting between departments to solve product problems. Inline and robotic production lines/ cells. Documented revisions and quality standards. Worked with Quality for developing of standards. Developed Testing and operator instructions. Development and build of test sets. Improve error proofing and updating production control plans/ FMEA’s. Supported soldering processes, induction heating and brazing, and robots, using metallurgical aspects of welding, Evaluated laser installations for other sites for corporate Laser Safety Officers. Served as troubleshooter for other divisions at request of Chief Engineer. Designed and built various tooling for cost effective process for production. Presented safety and application classes. Performed concept and feasibility studies for developing new projects, including writing business cases, time schedules, machine qualifications, documentation, ergonomics, apportions of funding, designing test experiments. Maintained QS 9000 documentation and procedures.

Accomplishments:

Reduction of high scrap rates and excessive production downtime, resulting in 5 million-dollar savings, improved product

quality and a 30% decrease in downtime.

Reduction of coining dies rebuild by 40% with design of experiments.

Received Shainin Journeymen Certification , this was received after four continuous improvement projects being reviewed and accepted.

Requested by Chief Engineer to assist the Coopersville plant with a resistive welding long term cause for rejects. The part was the plunger assembly for fuel injectors. With visual observations and time calculations found that the tooling was too slow in applying proper tip force before the weld start thus expulsion occurring. Sped up the fulcrum travel time and installed a pressure sensor. Reject rate was reduced by 30%

Assisted product teams for the AD237 stator core welding in process selection resulting in only a week startup/ debug time.

Charles Industries (IL) 1990-1995

Manufacturing Engineering Assistant

Product concept to production. Generated mechanical drawings and electrical schematics. Built prototypes, sales samples, test equipment and concept electronic circuits. Performed product testing (stresses, environmental, and functions), and generated formal reports. Developed and wrote operator and troubleshooting procedures. TIG, MIG, and resistive welding. Managed product quality control and returned goods repair. Provided machines setup and process development consulting services for other plants.

Accomplishments:

Reduced turn around time of returned goods to one week vice two week.

New Marine product launch was completed in three months vice a year.

Tested and built Ferro resident transformers/ power inductors, etc.

Education

*Associate of Applied Science in Electronics/ Lasers - Ivy Tech State College, Terre Haute, IN, 1994

*UAW Weld School, Anderson, IN, 1997

*Certified Journeyman Statistical Engineer, GM’s Red X- Shainin Consultants, Inc. 1997

* BS in Mechanical Engineering / Electrical minor- Cambridge State- August 2002

Seminars:

Lasers / Optics- Laser Welding and Cutting Supervision and Management

Problem Solving (Root Cause Analysis) Soldering and Printed Circuit Board Repair

Fatigue in Metals Geometrical Tolerance

Motoman Basic Programming Motoman Advanced Programming

Motoman PLC I/O Programming Centerline Resistive Welding

Motoman and Fanuc Programming

Affiliations:

United States Naval Reserves(retired), Rank E6

Disabled Veterans, Veterans of Foreign Wars

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