Manufacturing Engineer

Bruce J. Sieloff

***** **** **. **

Snohomish, WA 98296

*********@*******.***

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OBJECTIVE: To be a Change Agent for the organization determined to be recognized for World Class Quality

FOCUS Change and Innovation through Data Driven Lean Engineering-Pursuing Cost Reduction, Uninterrupted Operational Flow, Error-free Processing, Zero Significance Changeovers and the dedicated pursuit of improvements in Quality.

OVERVIEW

-Broadly experienced process improvement engineer with a 20-year record of success in operations and productivity improvement, including quality, manufacturing, production, administrative and service industry experience. Focused on finding waste in all forms and working better, faster, cheaper.

-Experience is augmented by a Masters Degree in Whole Systems Design from Antioch University, with tools, structures and process to uncover the different perspective, and suitable technologies to assist management in solving problems requiring a whole systems solution.

-Expert in systems/process design, cost-reduction strategies and transferable lean engineering skills. Known for innovative problem solving, complex troubleshooting and skillful relationship-building with client management and teams.

KEY SKILLS AND KNOWLEDGE AREAS

Production Organization/Management

Assembly Methods and Technology

Estimating/Pricing/Break Even Analysis

Planning, Scheduling, Quality, Delivery

SMED Rapid Setup

Process Re-Engineering

5S, ISO & SPC Systems / Tools

Work Flow/Cycle Time

Work Instructions & Software

Point of Production QA Proof

Process Qualification

Aurora/Delmia/Enovia/Velocity

DEMONSTRATED CAPABILITIES

- A CQI/Manufacturing/Quality Engineer in production, operations, quality assurance, fabrication, and assembly:

- Generating process improvements for mission critical projects and major initiatives.

- Incorporating corporate objectives in lean manufacturing and waste reduction.

- Value Stream mapping to identify and focus on customer value-added processes.

- Gain and sustain production improvements through Best Practices.

- Develop data driven decision making tools and lean progress measurements.

- Provide graphic analysis, project documentation and appropriate progress

- Training cross-functional teams to identify opportunities for improvement.

COMMON TOOLS AND PROCESSES

- Utilize Industrial Engineering technologies to reduce waste in manufacturing, distribution and administrative operations.

- Implementing Lean Manufacturing concepts and techniques; Kanban/JIT

- Methods Analysis for continuous cost reduction of labor, material and overhead

- Statistical Analysis to reduce variation, work flow and cycle time, track using SPC metrics

- Process Qualification to vette vendors for components, equipment and subcontracting.

- Facilities Management to coordinate facilities changes resulting from reengineered business and operations processes.

- Multi-task to plan, coordinate, manage and complete complex and simultaneous projects.

TYPICAL PROJECT RESPONSIBILITY

Perform as a team leader or member, facilitating team performance or as an individual contributor to define, target and achieve opportunities based on identified goals. Recommend alternative action plans, implement solutions; install pull production systems, improve shop layout, design criteria for manufacture, create assembly Kanban build authorities, generate standard work packages, and improve operation methods. Improving assembly operations, introducing shop aids and material handling improvements. Performing work measurement and capacity planning, restructuring workflow and facilities layout. Creating planning, scheduling, and facilities processes, organizational structures, visual tools.

RELEVANT EXPERIENCE AND ACCOMPLISHMENTS

9/2006-4/2009 Boeing Commercial Aircraft, Everett, WA.

Process Integration Manager

OPERATIONS ANALYSIS Contracted to perform Rate Readiness Reviews and operations preparation in Industrial Engineering for 777 production increases. Established tooling, staffing and space requirements, created new operations sequence and schedules to attain production increases.

PROCESS QUALIFICATION Charleston, SC. - Assisted 787 Partner Participation operations and quality documentation to prepare Global Aeronautica facilities and production system for receipt and completion of 1st 787 body sections. Established a consistent shop floor metrics management system, assisted in partner problem solving, consulted on production management development.

MANUFACTURING PLANNING Everett, WA.-Designed and accomplished planning and integration efforts in Change Incorporation and Refurbishment, establishing strategy and tactics to codify the statement of work and translate incoming change notices into an integrated manufacturing plan involving Electrical, Structural and Systemic components.

PLANNING AND INTEGRATION Performed planning and integration efforts in change incorporation and refurbishment, establishing strategy and tactics to define and codify the statement of work and translate incoming change notices into an integrated manufacturing plan involving electrical, structural and systemic components. Established a path and sequence strategy for wiring revision installation during refurbishment and for incorporating engineering change notices.

Key Results:

Delivered a process for a sequential work schedule that adapted to changes in volume, priority, flow time variations and available resources. Consistently commended for the quality, detail, accuracy and timeliness of deliverables such as:

- Creating Strategy and Tactics in Forecasting

- Capacity planning and Visibility communication

- Develop scheduling system for CI&R Process

- Value Stream Process Flow Diagrams

- ME Process Qualification/Verification

- CI&R Process Feasibility Studies

Achieved client objectives, including development of scheduling, measurement and visibility systems, forecasting capacity requirements, overseeing the results of the ME planning system and recommending improvements.

Worked with all levels of management and client teams to drive consensus, collaboration and forward momentum toward the completion of project milestones and the attainment of client goals.

10/2004 Present Custom Embroidery, VanityThreads LLC, Snohomish, WA.

ENTREPRENEUR Owner/Operator of a mobile Custom Decoration Business performing on site embroidery art at a variety of venues. Operated in 7 states in 2005, with revenues in excess of $100K. Sales, Marketing, Production and strategic positioning for custom embroidery operation specializing in high quality, low volume, personalized decoration of garments and accessories.

5/2003 4/2004 Quality Engineering, Protective Coatings, Inc., Kent, WA.

$10M Aerospace Coatings facility: Anodize, CAD, protective powder coating and aerospace paints.

* PROCESS CERTIFICATION Design and implement Quality Training for employees to meet requirements of NADCAP, National Aerospace and Defense Contractors Accreditation Program an enterprise critical certification.

* QUALITY ASSURANCE Interpret procedures, construct appropriate training process and develop competency tests.

* QUALITY ENGINEERING Assist Quality Assurance in quality engineering resolutions for manufacturing solutions to system problems.

* QUALITY TRAINING & TOOLS Expand 5S program, Develop PFMEA, assist 20% cost reduction target in production by year end.

* CORRECTIVE ACTION Improve systems via Corrective Action Requests, building a robust production process while eliminating weakness.

5/2000 4/2002 Lean Manufacturing Engineering at Vaupell Industrial Plastics, Seattle, WA. 98107

$30M Injection molding facility, specializing in advanced resins for aerospace and commercial application.

* SMED Instituted a mold setup reduction process, reducing press downtime by 40%.

* KITTING Managed an internship project to prepackage kits of Mold exchange materials, tools and accessories prior to changing molds.

* FORECASTING Structured a visual labor forecast production scheduling system that became the heartbeat of the molding process.

* LAYOUT ANALYSIS Authored the preparation and transfer of production line between facilities. revamped assembly layout and, material-handling methods.

* PROCESS QUALIFICATION Introduced new methods and equipment to meet the requirements of aerospace manufacturing standards and operator certification.

* JIT/KANBAN Introduced 5S systems in Molding and Assembly. Developed Kanban system for improving replenishment of aerospace products.

6/1993 5/2000 THE SIELOFF GROUP - CONSULTING

Offering the latest knowledge and techniques in removing identified barriers to increased productivity. Clients in metals fabrication, production printing, retail distribution.

Representative Clients:

BUSINESS PLANNING $20M custom job shop, fabricating plate steel industrial projects and sheet metal food processing equip.

- CHANGE MANAGEMENT Guided management team in design and implementation of comprehensive strategies, processes and changes.

- MARKETS Restructured business plan and identify new markets for growth in industrial steel vessel fabrication.

- TACTICS Created a common structure to reestablish project management as a core competency.

WORK FLOW AND FACILITIES DESIGN

$10M wholesale manufacturer of wood pallets and specialty storage containers

- METHODS Designed a tool-less setup for a production bottleneck.

- CONTROLS Improved the production control method to deliver accurate build criteria.

- LAYOUT Developed a master facility plan that eliminated 6-10 FTE.

- CAPACITY Acquired new capabilities (panel saw) to eliminate costly setups for small runs.

DISTRIBUTION SYSTEMS

$50M retail distributor of fine linens and household fabrics

- PROCESS ANALYSIS Evaluated the distribution process, implemented a new order picking system based on standard labor packages, redistribution of pick priorities and zone designated responsibilities. Results: My analysis led to the outsourcing of the corporate distribution chain, for 30% (multi-million dollar) annual savings.

PRODUCTION MANAGEMENT & QUALITY ASSURANCE

$10M production printing facility, specializing in state regulated and audited gaming products.

- REENGINEERING Boost output 30%, reduced staff 10% by reengineering a multicultural production line.

- SUPERVISION Improved output 110% in three months, demonstrating how to manage final assembly.

- FLOW ANALYSIS 50% reduction in flow time via material handling improvements and reduction of WIP.

- QUALITY ENGINEERING Slashed customer returns by 75% after installing and managing a Quality Assurance System.

- PROCESS QUALIFICATION Rejuvenated an unprofitable product, allowing Sales to create a lucrative new $1M+ market.

6/1986-6/1993 PROCESS IMPROVEMENT AT THE BOEING COMPANY.

CQI Specialist & Industrial Engineer at World-Class manufacturer of Commercial Aircraft, Aerospace and Defense.

- METHODS ANALYSIS Managed a handpicked team of specialists that saved $9 million/year.

- WORK MEASUREMENT Saved $250,000 per aircraft by cutting 240 hours and two days flow time.

- CAPACITY ANALYSIS Saved over $30,000 on each installation by alternative task sequencing.

- PROJECT MANAGEMENT Evaluated and recommended the installation of automated aircraft floor-drilling equipment that saved 15 man-days ($12,000) per aircraft drilled.

- SCHEDULING Reevaluated, estimated, planned and scheduled jobs and the task sequence and assignments of a 3 shift, 120 person crew, completing 747 body sections on schedule.

- MGMT DEVELOPMENT CQI developer; suggested, shaped, justified and implemented a 9-month Leadership Excellence training program for top Boeing line managers that combined CQI tools with skills in facilitating change (the program had a dramatic and measurable benefit to the careers of all graduates).

EDUCATION

MA Whole Systems Design, Organizational Re-engineering Antioch University 1990

BA Business Administration and Economics- Operations Research WA State University

KEYWORDS

TECHNICAL SKILLS

Advanced Quality Systems, Capacity Analysis, Capital planning and acquisition, CEDAC, Continuous Quality Improvement (CQI), Continuous Flow Manufacturing (CFM), Cost Reduction, Cost/Benefit Analysis, Forecasting, ISO 9002, JIT, Kanban, Methods simplification, MTM, New Product Introductions (NPI), Quality Functional Deployment (QFD), Operations and Production management, Planning, Poke-Yoke, Process Documentation, Project Management, Scheduling, Standards, Work measurement metrics.

Software - - Proficient in MS Word, MS Excel, Visio, Access, Fox Pro, 4th Shift MRP and MS Projects, Delmia, Enovia, Aurora.

TRAINING SKILLS

Criterion Referenced Instruction, Curriculum development, Deming Philosophies (PDSA/PDCA) of Variation, GOAL/QPC, Statistical Process Control (SPC), Instructional Design, Interactive approach, Leadership skills, Learning Styles, Meyers-Briggs, Organizational Development, Presentations, Process Consulting, Project Teams, Quality Improvement, Situational Leadership, Teaching, Joiner Teambuilding, Total Quality Management (TQM), Trainer/Designer.

CONSULTING SKILLS

Adult Learning, Changing behaviors, Coaching, Consulting, Cultural transformation, Customer Service, Experiential, Facilitator, Futuring, Group dynamics, Group process, Excellent Interpersonal behaviors, Open Space Planning, Large Systems Change, Managing Change, Organizational design, Organizational effectiveness, Overcoming Resistance, Process consulting, Strategic visioning, Strategic Planning.

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