Engineer Manager

DAVID PELLETIER

**** ***** ****** * ( Farmington, Minnesota 55024

651-***-**** ( ********@*****.***

ENGINEERING MANAGER / SR. PROCESS DEVELOPMENT ENGINEER ~ LEAN MANUFACTURING

Innovative, customer and quality-focused Manufacturing Engineering

Manager/Quality Manager with 18+ years experience as a Continuous

Improvement leader and Quality Engineer for manufacturing organizations

with a masters degree in engineering. An analytical problem solver and LEAN

Manufacturing specialist who analyzes systems challenges, identifies

process improvements and drives strategic Quality planning to meet client

and corporate objectives. Superior leadership skills, expert in directing

cross functional teams to design and deploy projects driving operational

excellence, efficiency and cost savings. Proven areas of expertise include:

Operations/Manufacturing Management ( Just In Time (JIT) ( Change

Management ( Process Simulation

Multi-Project Management ( Team Leadership ( Root Cause Analysis (

Continuous Improvement ( Testing

Cost Reduction ( Training Development ( Problem Solving ( Quality System

Development ( Automated Processing ( FMEA ( DOE ( SPC ( CAPA ( MRB ( Gage

R&R

New Product/Process Introduction ( Budget/Fiscal Management ( Process

Design/Improvement

PROFESSIONAL EXPERIENCE

Valmont Industries, Farmington, Minnesota ( 2009 - 2012

Manufactures built-to-order light poles and flag poles for commercial and

DOT customers world wide.

Quality Manager / Manufacturing Services Manager

Managed departments in charge of Quality, Safety, Ergonomics, Lean,

Security, DOT Compliance, Continuous Improvement and Maintenance. Led

large, cross-department teams to improve capacity, reduce costs, raise

suppliers' performance, reduce customer quality occurances, increase

product flow, eliminate downtime and upgrade process capabilities.

Financial/Operational Highlights:

. Cut customer quality occurance rate from 3% to 0.7% over 3 years.

. Reduced year over year costs by 1 to 2% of sales each year for 3

consecutive years.

. Increased plant capacity by 50% without adding capital equipment.

. Led improvement teams to achieve Potential Center of Excellence status

and then on to Center of Excellence status for the Farmington plant (C of

E is based on Shingo Award criteria).

. Created new designs for flag poles and light poles that increased

durability and longevity as well as lowered production costs and

processing time. Designed and developed the process to produce these new

designs.

. Managed Safety depertment that achieved MinnStar status with OSHA.

. Brought our plant into compliance with new client DOT's (state and city)

and kept our plant in compliance with existing client DOT's (state and

city).

. Managed supplier improvement program greatly improving supplier

performance for quality and delivery

. Mentored department members into outstanding employees

. Continually promoted to positions of increasing responsibility throughout

tenure due to superior performance.

HUTCHINSON TECHNOLOGY, Hutchinson, Minnesota ( 1997-2009

Manufactures high volume, precision, electromechanical components through

highly automated processes for hard disk drives and also devices for the

biomeasurement/medical industry.

Senior Process Development Engineer (2002-2009)

Led large, cross-department, capital projects consisting of analysis and

enhancement of current process or equipment in order to reduce cost,

improve yields, improve cycle time and product traceability. Performed end

to end financial management for project budgets, tracked forecast vs.

actual spent. Generated buy-in from management, teams and stakeholders.

Oversaw all project tasks, schedules and workplans, ensuring project team

members participation. Managed new automated process and machines from

design to production. Modified processes, routings, procedures and

equipment to prevent product contamination in critical areas. Provided on-

time and on budget delivery of projects.

DAVID PELLETIER ( Page 2 ( ********@*****.***

HUTCHINSON TECHNOLOGY, Hutchinson, Minnesota ( 1997-2009 - con't

Financial/Operational Highlights:

. Spearheaded product traceability project yielding $5M savings annually,

revamped method of identifying defects improving yield 3%, capacity at

bottleneck processes 5-20%.

. Eliminated costly label application processes resulting in $3.3M cost

savings.

. Achieved continuous improvement through DOE, statistical analysis, root

cause, fishbone studies and situation/decision analysis.

. Developed 2nd generation suspension adjust process, virtually eliminating

customer returns, improving capability 65% and yield from 96.5% to 99.5%.

. Designed a new shearing technology that extended tool life 500%, improved

capability 50% and generated over $1M in cost savings.

. Decreased tooling costs $200K/annually and cut set up time by 70%.

. Continually promoted to positions of increasing responsibility throughout

tenure due to superior performance.

Industrial Engineer (2000-2002)

Developed product/process models for new products in order to estimate and

improve performance. Served as Subject Matter Expert (SME) for Ergonomics

and Contamination Control. Designed production floor layouts. Implemented

general process improvements, analyzed and identified continuous

improvement projects.

Financial/Operational Highlights:

. Analyzed all quarterly costs, including overhead in order to quantify

project prioritization for the department.

. Modeled new processes and products to focus improvement projects prior to

and during initial development.

Supplier / Quality Engineer (1999-2000): Enabled tooling suppliers to

create and improve quality systems to improve the quality of incoming

tools. Assisted suppliers with complex procedures.

. Reduced incoming defects by 20%.

. Improved supplier measurement techniques and created an inspection

reduction plan in order to avoid having to re-check supplier

measurements.

. Achieved Top Performer for the department.

Quality Engineer (1998-1999): Refined tool qualification processes for

quicker product start times. Developed and implemented qualification

procedures and ensured compliance. Processed customer returns for tooling.

Identified and resolved tooling suppliers' quality issues.

. Created Functional Reject and Corrective Action System (FRACAS), reducing

customer returns 60%.

. Instituted functional tooling qualifications and tests, reducing returns

50% and improving product start up time by 20%.

. Led Material Review Boards for the disposition of non-conforming material

Industrial Engineer (1997-1998): Created machine build methods and

procedures to improve throughput time and resolved back-up issues to

increase efficiency and help teams meet their production goals. Improved

overall floor layout, reconfigured warehouses for maximum storage and

efficiency. Optimized work flows, resolved many long standing issues,

prohibiting production from reaching their full potential.

. Doubled machine storage capacity and improved machine build time from 200-

900% in order to meet goals.

. Aided slower machine technicians to achieve production goals through

training and best practice improvements.

HIBBING ELECTRONICS, Hibbing, Minnesota ( 1994-1997

Contract manufacturing company servicing electronic, computer, automotive,

gaming, HVAC and various industries.

Just In Time Program Engineer (1997): Established plant wide Just In Time

strategies in order to cut cycle times, set up times and remove waste from

all production processes in order to increase efficiency. Performed in dual

roles as Manufacturing Engineer simultaneously.

. Launched Kanban systems on steady products for just in time delivery.

. Reduced set up time for high speed machines by 50%.

DAVID PELLETIER ( Page 3 ( ********@*****.***

Hibbing Electronics, Hibbing, Minnesota ( 1994 - 1997 - con't

Manufacturing/Quality Engineer (1994-1997): Coordinated the conversion of

customer documentation into company standard prints, BOMs and work details

for production operators. Supervised up to 10 technicians, designed

production layouts for assembly areas, and investigated customer returns.

Implemented corrective actions where necessary. Collaborated with customers

and suppliers to replace obsolete components. Improved yields, led quality

action teams. Served as SME for regulatory auditors (ISO, UL, CSA, etc)

during all plant visits and inspections. Developed functional product tests

based on end user requirements.

. Leveraged an off the shelf item to replace a component previously made by

hand, freeing 10+ full time operators and saving $1M annually.

. Instituted Quality Action Teams, resulting in decreased customer

complaints from 175/per week to less than 10/per week.

. Achieved consistent success improving yields and reducing costs.

EDUCATION/TRAINING

Master of Manufacturing Systems Engineering, University of St. Thomas, St.

Paul, Minnesota

Bachelor of Science in Industrial Engineering, Minor in Mathematics,

University of Minnesota, Duluth, Minnesota

Proficient in MS Word, Excel, Access, PowerPoint, Visio, Outlook, Project,

Minitab V14,

Promodel Simulation, Design Ease; Functional knowledge of Autocad and Pro-E

EIT Certified

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