Manufacturing Engineer

BRIAN LUKAS

*** ******* ***** *** */Greenwood, IN 46143

317-***-**** m2dyk8@r.postjobfree.com

Process Engineer- Manufacturing Engineer – Product Launch Engineer

Effective self-starter demonstrating over 25 years of solid experience across varied product launches, services and technologies. Creative, highly energized professional with outstanding visionary problem solving ability. Combines “hands-on” technical qualifications with consistent success in identifying opportunities for product launch for tier 1 and 2 automotive suppliers.

PROFESSIONAL EXPERIENCE

MANUFACTURING LAUNCH ENGINEER

Hella Electronics Inc./Flora, IL 2005 –2009

A world-class designer and manufacturer of Tier 1/ Tier 2 automotive electronic circuits, assemblies and sensors.

· Expert in the required processing technology to meet the required production rate, volume, quality levels, economy, timetable and resources.

· Created and maintained process FMEAS for all process designs.

· Originated the needed fixtures, machines, equipment and tools through internal or external sources to develop the process concurrently with the product to meet established build schedules.

· Arranged installation and start-up of production equipment and provided means of training personnel on its operation and service.

· Led in the research, development and implementation of a new manufacturing line at a cost of $2.0 M in the assembly of a Global seat control module for GM. Manufacture and assembly included top and bottomside SMT, selective soldering, flash, route, pressfit, ICT, conformal coat, housing assembly, EOL/label and pack. Resulted in $150 million annual sales.

· Led in the research, development and implementation of a new manufacturing line at a cost of $.75 M in the assembly of a seat control module for a new customer. Manufacture and assembly included topside SMT, ICT/flash/calibrate, shear, pressfit, conformal coat, housing assembly, EOL/label, and pack. Resulted in $6.0 million annual sales.

· Saved $.5M in manufacturing equipment cost by combining the backend manufacturing lines of both projects to utilize common manufacturing equipment.

· Improved efficiency and repeatability of conformal coating spray equipment via retrofit of machines with dual toggle head swirl coat & precision jetting nozzles saving $250K/yr in rework and scrap.

· Reduced rework and scrap cost via implementation of multi-lead soldering technology equipment saving $50K/yr.

PROCESS ENGINEER

Raytheon Technical/Indianapolis, IN 2003-2005

Raytheon is an industry leader in defense and government electronics, space, information technology, technical services, and business aviation and special mission aircraft.

· Develop manufacturing processes and flow, provide bid support, tool and fixture design, poke yoke processes, lean manufacturing and implement these processes into the manufacturing environment.

· Participated in multiple PCB and Final Assembly program launches to the manufacturing floor.

· Arranged installation and start-up of production equipment and provided means of training personnel on its operation and service.

· Successfully launched the build of IFCS and RAMS utilizing lean manufacturing processes saving 20% in overall cost of PCB assembly processes.

· Provided technical expertise in the build of printed wiring boards overseeing the correction of production build issues.

NOTE: Let go due to corporate downsizing

Brian Lukas Page 2

PROCESS ENGINEER

Millennium Industries/Ligonier, IN 2002

A Tier 1 & 2 manufacturer of automotive fuel systems, rails, reservoirs and components.

· Developed/Implemented and maintained manufacturing processes/equipment and flow, process FMEAS, poke yokes

· Specified/Sourced capital equipment, tool and fixture design

· Ran capability studies, gage R&R’s

· Arranged installation and start-up of production equipment and provided means of training personnel on its operation and service.

· Participated on APQP teams in the implementation of new production lines including flatten & pierce, bracket weld, fuel cup weld, barb stake & endcap, braze, final assembly, and final test and mark for manufacture of stainless steel tube fuel rail line.

· Successfully launched and integrated the use of laser welder and tooling for the support of new in-house technology in the sealing of tubular automotive fuel rails for Ford with internal dampers.

NOTE: Let go due to corporate downsizing

CONTRACT MANUFACTURING ENGINEER

Teleflex Automotive/Kendallville, IN/Lyons, OH 2001- 2002

Tier 1 designer and manufacturer of driver control systems, accelerator pedals, electronic throttle control systems, shifter assemblies, control cables, wire controls, and powered adjustable pedals for the automotive industry.

· Analyzed present in-house operations and made recommendations as to changes to present manufacturing equipment/assembly techniques, to justify new equipment and layout required incoming inspection criteria. Processes included heat staking, soldering, lubrication, rotor insertion, laser trimming, RTV gasketing and related processes.

NOTE: Automation integration project was put on hold due funding freeze, position eliminated.

SR. PROCESS ENGINEER

Wabash Technologies/Huntington, IN & Mexicali, Mexico 2000 -- 2001

A leading Tier 1 & 2 manufacturer of a broad range of vital electronic/electromechanical components for original equipment manufacturers.

· Maintained process flow charts, process instructions and operator training

· Originated the needed fixtures, machines, equipment and tools through internal or external sources to develop the process concurrently with the product to meet established build schedules.

· Developed manufacturing processes, process FMEAS, poke yokes on processes

· Established bids, capability studies, gage R&R’s

NOTE: Let go due to corporate downsizing.

SR. PROCESS DESIGN ENGINEER

VDO Control Systems, Inc./Auburn, IN 1990 – 2000

A world-class designer and manufacturer of Tier 1 automotive electronic circuits, assemblies and sensors.

· Researched and identified current available manufacturing methods and matching the specific needs for manufacturing of the product to appropriate technologies.

· Developed expertise in the required processing technology to meet the required production rate, volume, quality levels, economy, timetable and resources.

· Created and maintained process FMEAS for all process designs.

· Originated the needed fixtures, machines, equipment and tools through internal or external sources to develop the process concurrently with the product to meet established build schedules.

· Arranged installation and start-up of production equipment which included setup programming and debug of equipment and provided means of training personnel on its operation and service.

· Led in the research, development and implementation of a new manufacturing process technology at a cost of $1.7 M in the assembly of a no-lead double sided SMT flex foil product for BMW capable of meeting there high temperature in the engine operating requirements on the VVT Sensor Assembly. Manufacture and assembly included top and bottomside SMT, ICT, laser trim, depanel, housing assembly, selective soldering, vacuum encapsulation, cover assembly and final test and mark. Resulted in $10.0 million annual sales.

· VVT sensor selected as Best New Technology Introduced within VDO Automotive Powertrain in 2001.

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· Participated on APQP team in the implementation of new automated line including odd-form assembly, bottomside SMT, wave soldering, final assembly, final test and mark for manufacture of electronic compass.

· Provided technical expertise in the launch and implementation of new automated double sided SMT line for the manufacture of electronic Airbag modules with no touch-up to all goals and timelines at a cost of $ 1.5 M which resulted in $ 12.0 million annual sales and a soldering defect level of less than 10 PPM.

· Airbag module launch selected as Philips Quality Customer Champion within Philips in 1995.

· Participated on APQP team in the implementation of new automated PCB assembly line including axial, radial, SMT, through hole hand assembly, soldering, touch-up and final test for the manufacture of electronic ballast that was launched in less than 10 months.

· Successfully launched/ integrated the use of laser trimmer technology in the active trimming of automotive modules for Ford and Honda.

PROCESS KNOWLEDGE

ISO/QS9000

Lean Manufacturing

Demand Flow

APQP

PPAP’s

FMEA’s

DFM

Cross Functional Teams

SPC

Kaizen

Control Plans

Flow Charts

ACAD

Processes/WOI’s

Poke Yokes

Capability Studies

Gage Studies

Quotes & Bids

Screenprint Pick&Place Reflow

Thru-hole

Component Prep

Wave Soldering/Selective Soldering

6S

Pressfit

Conformal Coating

IPC-610/J-STD’s

Training

Encapsulation

Injection Molding

Preventive Maintenance

Procurement Spec’s

Wire Prep

Coil Winding

EDUCATION/PROFESSIONAL DEVELOPMENT

Bachelor of Technology – Mechanical

S.U.N.Y. at Binghamton, NY

Associates of Applied Science – Mechanical

Broome Community College, NY

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