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Engineer Manufacturing

Location:
Summerville, SC, 29485
Salary:
$110,000.00
Posted:
August 14, 2012

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Resume:

JOHN EDWARDS

**** ********** ***** • Summerville, SC 29485

Cell: 843-***-**** • lmj1cd@r.postjobfree.com

SENIOR MANUFACTURING ENGINEER

Versatile, resourceful, and goal-oriented Senior Manufacturing Engineer with extensive hands-on experience developing, implementing, and evaluating production processes and necessary process controls from initial conceptualization through launch and ongoing operation. Proven results in upgrading and creating reliable, repeatable, capable, and cost effective processes through parameter optimization, tool design and selection, fixture design and development, gauging and equipment selection. Self-directed team leader capable to build strong working relationships with all stakeholders. Able to see the big picture, focus on the critical details, and prioritize multiple projects in high-pressure, deadline driven environments. Committed to exceeding expectations through creative idea generation, collaborative problem solving, and disciplined decision making.

AREAS OF EXPERTISE

• Project Management • High Precision CNC Machining • Process Mapping

• Six Sigma Methodologies • 8-D Problem Solving • Team Leadership

• Identify & Eliminate Waste • Tool & Fixture Design • Cost Reductions

• Lean Manufacturing • APQP / PFMEA / Control Plans • Facility/ Cellular Layout

• Kaizen Techniques • TS/QS/ISO/FDA Compliance • GD&T

PROFESSIONAL EXPERIENCE

CONTRACT ENGINEERING, Knoxville, TN, Nashville, TN, Beaufort, SC • 2009 – Present, 2007-2008, 2003-2005; (All obligations satisfied)

Senior Advanced Manufacturing Engineer

Resolved tooling, gauge, fixture, and process quality capabilities using Six Sigma, 8D’s, and SPC. Implemented new products and processes utilizing APQP procedures with Process Flow Charts, PFMEA, Control Plans, Gant Charts, MSA, and all other APQP tools. Planned and developed protocols, documents, tools, fixtures, and equipment for high volume machining, stamping, assembly, and welding. Initiated and lead teams to resolved safety, quality, and productivity issues through proven engineering and root cause analysis.

• Engineered improved flow, error-proofing, and defects reduction from 500 PPM to 20 PPM in 12 months.

• Launched 15 new products; meeting initial PPAP date with document, gage, capability, and product approval by the customer.

• Performed Gap Analysis, identifying and eliminating seven kinds of manufacturing wastes.

• Performed process improvements; reducing PPM defects from 10000 to 500 in 18 months.

EXACTECH INC., Gainesville, FL • 2008 – 2009 (Reduction in Force)

Senior Manufacturing Engineer

Built tools and fixtures, implemented processes, and authored quality documentation for new product launches including Standard Operating Procedures, Engineering Standards, Process Work Instructions, lot control, record maintenance, and preparation of FDA submissions.

Championed process capability, gage R&R, and quality improvements for current and developing products. Wrote procedures and protocols for GMP, SPC, PFMEA, record maintenance, product inspection, and process control documentation.

Developed, wrote, and performed Process Validation and Verification including Installation Qualification (IQ), Operational Qualification (OQ), and Process Qualification (PQ). Conducted on-site visits to domestic suppliers to implement tooling, quality, cost, and process improvements. Reduced PPM defects resulting in $100K savings.

• Served as Team Leader (Quality, Manufacturing, Manufacturing Engineering, and Product Engineering) for set-up reduction program for knee implants reducing time from 45 to 15 minutes.

• Led the design and build of automated Fluorescent Penetrant processing equipment and an inspection station that generated a $4.00/part cost savings and drove further in-sourcing of product.

• Developed manufacturing processes and protocols for the Equinox Shoulder System in house processing.

CVG – NATIONAL SEATING, Vonore, TN • 2006 – 2007 (Reduction in force)

Division of Commercial Vehicle Group producing showcase air ride suspension seats for commercial truck OEMs.

Senior Process Engineer

Designed tooling, equipment, and managed budgets for the successful launches of many new products. Developed TS and QS documentation including lot traceability, programs, PFMEAs, Control Plans, and work instructions. Traveled to domestic and international customer and supplier facilities implemented new tooling, improved supplier quality, reduced cost and lead-time of outsourced product. Initiated, lead teams, and resolved 8-D quality issues providing customers with containment and permanent corrective actions.

• Dramatically improved defect rates from 500 PPM to less than 50 PPM in eight months.

• Developed and managed new tooling and products for CVG’s China Operations.

NORTEK INDUSTRIES, Maryville, TN • 2005 – 2006 (Company sold. New owner brought own management staff)

Automotive Tier II safety restraint stamping supplier.

Engineering Manager

Supervised a staff of 11 including Tool & Die Journeymen, Maintenance Technicians, and Engineers. Developed ISO 9001 procedures for Tooling, Maintenance, and Engineering Departments. Managed all facility maintenance, tool design, and manufacturing engineering.

• Reduced set-up times two hours from last-off to first-off through lean principles and automation.

• Refurbished 35 dilapidated progressive stamping dies to customer quality specifications and completed project under budget and within planned lead-time.

SIEMENS DIESEL SYSTEM TECHNOLOGY, Blythewood, SC • 2000 – 2003 (New programs cancelled)

Tier I manufacturer of diesel fuel injectors for International Harvester and Ford Motor Company.

Senior Advanced Manufacturing Engineer

Managed a staff of 15 including Manufacturing Technicians and Team Leaders in the Machining Department. Project manager for the selection and installation of six high precision ten station rotary CNC machining equipment worth $20 million, including process development, tool design, fixtures, programming, and APQP. Developed and implemented six automatic hard turning with post process gaging replacing a plan for conventional grinding that yielded $16 million in capital equipment savings and $300K in annual operating cost savings. Improved major processes resulting in $15 million in capital savings and $400K in annual cost savings through tooling, fixture, and process modifications.

• Initiated, lead teams, and resolved 8-D quality issues. Initiated and lead root cause analysis teams.

• Provided reports of short term and permanent corrective actions to OEM customers.

• Key Six Sigma team leader on machining improvement project resulting in $5 million annual savings.

MAJOR TOOL COMPANY, Knoxville, TN • 1999 – 2000 (Reduction in force)

Distributor of machining, tooling, and accessories.

Outside Sales Engineer

Supported manufacturing companies with professional sales and engineering expertise. Tested machine tools to reduce production costs and tooling expenses. Resolved customer’s machining, work holding, and processing issues. Documented cost savings generated from tooling changes, accessories, and cycle time reduction. Authored and presented proposals to customers for cost savings and implementation.

• Increased territory sales from $100K to $850K in nine months.

YALE SECURITY, Lenoir City, TN • 1993 – 1999 (Recruited by Major Tool for better incentives and advancement).

Manufacturer of commercial and residential lock hardware.

Senior Manufacturing Engineer

Project leader for conceptualizing, specifying, and managing a $4 million capital investment in high-precision CNC machining and turning. Directed process development, tooling, fixtures, programs, and APQP documents. Wrote TS/ISO documents for project management, equipment specifications, and work instructions.

• Generated $400K in capital savings and $75K in annual tooling savings.

• Developed and implemented 10 axis CNC Swiss turning processes over conventional turning, followed by manual milling, drilling, and broaching lock cylinder plugs, yielding a $5 million capital equipment savings, a $2 million one-time inventory savings, and $400K in annual labor and overhead savings.

• JIT and Kanban team leader on continuous improvement projects yielding $250K in annual savings.

• Produced $200K in annual savings through tooling and process improvements on conventional single and multi-spindle machining equipment.

EAGLE BEND MANUFACTURING/MAGNA INTERNATIONAL, Clinton, TN • 1990 – 1993 (Recruited by Yale)

Manufacturer of automotive tier I structural metal stampings and welded assemblies.

Manufacturing Engineer / Program Manager

Orchestrated major model year changes for an $18 million annual CT-120 Ford Motor Company program including product and tooling quotations, writing tooling and equipment specifications, managing equipment and tooling builds, equipment and tooling acceptance.

Spearheaded a $12 million annual sales program for SN-95 Mustang launch with 56 stampings and 10 welding assemblies for Ford Motor Company. Organized and led the implementation team which included Tooling Engineers, Quality Engineers, Tool and Die makers, Assembly Engineers, and Manufacturing Technicians.

Collaborated with vendors, peers, management, customer engineering, and purchasing on all aspects of the Ford business, including product, gage, and tooling specifications, and quotations. Developed work instructions, gage instructions, and all APQP documentation. Reported weekly status to management and Ford on program launch. Maintained process documentation, engineering changes, purchase orders, incurred costs, and communications.

• Domestically sourced components made from special material for a safety critical product utilizing statistical strength comparisons and vehicle crash test validation generating $2 million in shared annual savings.

• Initiated, lead teams, and resolved 8-D quality issues. Initiated and lead root cause analysis teams for problem solving. Provided reports of short term and permanent corrective actions to OEM customers.

CARRIER CORPORATION - ALLIED PRODUCTS DIVISION, Knoxville, TN • 1988 – 1990 (Recruited by EBM)

Manufacturer of commercial and residential heating and cooling equipment.

Manufacturing Engineer / Production Supervisor

Led 50 production, quality, and engineering technicians on four assembly lines. Maintained employee records, handled performance evaluations, disciplinary actions, and employee recognition. Ensured a safe work environment through ongoing maintenance and use of best ergonomic practices. Reported daily productivity to management. Created work instruction visual aids for each operation on various products. Utilized pre-determined time standards and time studies for optimal line balancing.

• Reprocessed and revised documentation of current products increasing productivity by 10%.

• Launched a new electric heat program with an overall reduction of 25% in costs versus plan.

VOLUNTEER TOOL & DIE, Cookeville, TN • 1986 – 1988 (Recruited by Carrier Corporation)

Manufacturer of metal stampings and machining for Water Heating Industry.

Engineering Manager

Directed two Tooling Engineers, four quality technicians, and three maintenance technicians with responsibility for implementing engineering changes, safety training, quality, and process improvements. Responded to customer quality concerns. Conducted quality training for machine operators. Developed written protocols and quality plans for all products. Documented product validation, verification, procedures, and work instructions.

• Established predictive tooling maintenance based on trend analysis of recorded dimensional data.

• Implemented QDC training for setup technicians that reduced press changeover times from 2 hours to 30 minutes with zero capital investment.

EDUCATION

BS Industrial Engineering - Tennessee Technological University, Cookeville, TN

SPECIALIZED TRAINING

Six Sigma for Green and Black Belt Team Training

EIA/ISO and Conversational Programming for Turning and Milling

Toyota Just-in-Time Manufacturing, Lean Manufacturing & QS 9001

APQP, TS16949 Quality Operating System, ISO 14001 Environmental

ASME Y14.5-2009 Geometric Dimensioning and Tolerancing Certification

COMPUTER SKILLS

AutoCAD, Mechanical Desktop, Solidworks

Microsoft Office 2007, MS Project 2003

MiniTab Statistical Software, MPACT APQP Software



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