Industrial / Manufacturing Engineer, Lean Six Sigma, Change management

Ken Hurd

Objective:

An opportunity that will allow me to utilize my engineering experience, Lean Six Sigma manufacturing expertise, management background, problem solving, and leadership skills to drive operational excellence for a goal-oriented company.

Experience / Focus Areas:

Manufacturing / Industrial Engineering, Safety, Lean Six Sigma Methodology, Kaizen, 5S, Project Management, Cost Reduction, Process Improvement, MRP, Training, Visual Factory, Work Measurement, Inventory, Automation, Field Service

Education:

B.S. Industrial Engineering Technology, Southern Illinois University (3.75 GPA)

Equivalent A.S. Missile Maintenance Technology and Applied Science, Community College of the Air Force.

Career Accomplishments:

Drive lean mfg initiatives, lead cross functional/ Kaizen Teams, HAZMAT response team, facilitate changes. Identify gaps & initiate improvements. Consolidated two mfg facilities. Introduced product lines, completed line moves, & line start-ups. Manage cost reduction projects. Drive quality & capacity improvement and facility cost reductions. P&ID, facility layout.

Employment History:

Senior Manufacturing Engineer (9/08 – 08/09) Infinia Corporation, Kennewick, WA

Responsible for the production of solar powered free-piston Stirling generators. Key contributor in the design and implementation of production lines to include utilities, piping, and conveyor systems. Developed safety practices and policies. Implemented lean mfg and process improvement to include transition from prototype to sustained production. Reviewed ECR’s and coordinated with design engineers to ensure manufacturability. Introduced new processes, equipment, and tooling used in production. Performed Risk Analysis. Developed business processes and work methods.

Vice President, Production Operations (10/07 – 8/08) Omega Systems, Inc., Phoenix, AZ

Responsible for production operations, facilities, safety and environmental health practices and policies for assembly of Communication systems. Developed business processes and maintained budgets. Directed lean mfg initiatives, process improvements and transitions from prototype production to sustained production. Directed supplier quality. Directed design engineers and ensured manufacturability. Directed material and production operations systems in multiple locations.

Manufacturing Engineer (2/05 – 10/07) Aviation Communications and Surveillance Systems (ACSS), Phoenix, AZ

Responsible for mfg FAA regulated RF aviation systems (TCAS, RF Antennas, ATDL, IFF). Principle leader for implementing change using lean mfg initiatives. Directed Kaizen and 5S events; introduced Kan Bans and process improvements. Participated in MRB, supplier quality reviews, and CCB. Reviewed ECR’s and coordinated with design, software, and systems engineers to ensure manufacturability of electronic components. Evaluated new processes, equipment, and tooling used in production. Directed X-functional teams between product lines. Initiated stock reductions and improved time to market, reduced FGI using Pull systems, and drove reductions in cycle time. Improved the MRP system to meet demand while decreasing inventory. Improved packaging for FGI shipping and reduced corrugated usage by implementing reusable containers. ACSS is an L-3 Communications Company.

Industrial Engineer (10/03 – 2/05) American Express Service Delivery Network, Phoenix, AZ

Analyzed processes & provided solutions to complex issues, to include driving improvements that resulted in over $2m in saves for a customer service call center. Used Six Sigma methodology to drive operational excellence. Guided Kaizen teams in redesigning processes & implementing automated systems. Performed process audits, metrics & capacity analysis.

Manufacturing Engineer (10/01 – 10/03) Tyco Fire Products, Lubbock, TX

Responsible for the production of fire protection devices. Drove operational excellence in process improvement, designed processes and implemented automated systems. Performed process audits. Created BOM’s, routings, FMEA’s, and work instructions. Developed run charts and quality control plans. Planned and conducted prototype/pilot production runs. Introduced products to mfg from design including fixtures/stations. Directed equipment line moves/prep, and designed plant layouts utilizing AutoCAD for a plant consolidation of 2 facilities. Performed "Root Cause Analysis" and determined resolutions for mfg issues. Managed projects, capacity analysis, throughput and quality improvement using Six Sigma methodology. Designed work cells using lean concepts. Participated in MRB and supplier quality reviews. Responsible for work cells, packaging, automated soldering, paint/powder coating lines, tooling design and implementation.

Process Engineer / Area Training Coordinator / Sr. Maintenance Technician (7/95 – 10/01) Micron Electronics (subsidiary of Micron Technology, Inc.), and Micron Technology Inc; Boise, ID

Developed training requirements, operating policies, safety practices and maintenance procedures as a member of the mgmt team for a mfg support group providing Total Gas Management (TGM) in the delivery of hazardous gases for the mfg of semi-conductor devices. Developed a comprehensive turnkey training and certification program to include curriculum and procedures. Provided safety, orientation, and gas systems related training and established technical certifications. Subject matter expert for high purity gas systems maintenance and hazardous incident response. Presented team building training events to improve efficiencies of the group. Certified Sr. Technician for gas systems and equipment to include flow controls and automated systems. Confined space and SCBA certified. Ensured compliance with ISO 9000 policies. Planned, implemented, directed and tracked projects to improve the efficiency, capacity, and product quality of an electronics mfg company. Implemented automated systems. Doubled the capacity using “Lean” principles resulting in $3.5 million facility cost savings. Utilized teams to improve process efficiency, capacity and product quality of electronic devices. Participated in inventory control and material handling improvement projects (PTL and conveyor systems). Initiated and managed cost reduction projects. Performed process audits and cycle time studies. Created and maintained on-line process work instructions, statistical process controls, and work standards. Responsibilities included the Final Assembly, Repair, Test, and Packaging departments.

Field Service Engineer / Site Manager (10/90 – 7/95) AAI / Engineering Support, Inc; Boise, ID

Shift Supervisor (10/88 – 10/90) Ford Aerospace, Inc., Silverdale, WA

Site Manager / Field Service Engineer (10/86 – 10/88), Lear Siegler, Inc; RAF Greenham Common, England

Site Manager and Field Service Engineer responsible for fixed site operations and remote unit repair of sophisticated electro-mechanical systems. Responsibilities included staffing and supervising maintenance support techs. Ensured compliance with DOD contracts and Statement of Work (SOW). Provided technical electronic/mechanical maintenance support on simulators for the US Army (M1A1 and Bradley Fighting Vehicle) to include displays and audio. Supervised maintenance, repair and equipment support operations on sophisticated training devices and hydraulic actuated motion simulators for the U.S. Navy Trident Training Facility. Responsible for eight maintenance techs performing repair and PM using specialized test equipment and maintenance repair techniques on displays and computers. Developed and tracked PM schedules. Performed high level electronic/mechanical systematic troubleshooting, PM, and system repair. Site Manager of on-site operations and staffing in a supporting contract role with McDonald Douglas. Managed site operations and provided tech support, depot level repair, and modifications on the Tomahawk cruise missile systems and associated equipment for the U.S. Air Force including batteries (NiCad), HVAC, linear actuators, gas turbine generators, missile guidance sets, and nuclear warheads.

Technical Instructor and Missile Maintenance Technician, USAF (8/77 – 10/86) Great Falls, MT – Tucson, AZ

Senior Missile Maintenance Technician, Certified Master Tech and Instructor for the Minuteman and Tomahawk nuclear missile weapon systems. Dispersal Maintenance/Academic Instructor (10/84 – 10/86) on the Tomahawk short-range nuclear missile system. Responsible for dispersed units of over 100 personnel in wilderness living conditions and training in the Arizona desert and high desert mountain region. Technical Instructor, Senior Planner, and Missile Maintenance Technician (8/77 – 10/84) providing maintenance training, planning, and maintenance on the Minuteman Missile nuclear missile system. Responsibilities included supervising 5-person teams maintaining the Minuteman missile in Montana. Planner/Scheduler for maintenance, proof load testing and non-destructive testing of equipment/support systems for the Minuteman missile system.

Training Courses: Six Sigma Methodology Black Belt Certification Training, Lean & Cellular Mfg, Metallurgical Soldering & Brazing Techniques Workshop, ERT Training, Hazardous Gas Incident Coordination, NCO Leadership School, HR Mgmt and Mgmt Communications, USAF Supervisor Development Course.

Skills and Experience: Excellent communication and leadership skills. Competent with most computer software programs. First line supervision/mgmt team experience. Process flow, capacity planning, plant layout, cellular and lean mfg. Material handling experience and knowledge. Pick-to-Light order fulfillment, inventory control, packaging methods, RF and bar code scanning background. FMEA experience. PPAP experience. Thorough understanding of OSHA, NFPA, UL, FM, and ISO policies and how to communicate effectively with their agency representatives. Planning and scheduling. Flow control systems and automated control unit troubleshooting and repair. Pneumatic, hydraulic, electronic, computer hardware, and specialty equipment repair and maintenance.

Computer Software: Visual, Minitab, Word, Excel, Access, Project, PowerPoint, Outlook, Visio, AutoCAD, Allen Bradley and Rockwell Automation. Professional Memberships: Senior Member of the Institute of Industrial Engineers (IIE)

Summary of Experience

I was recently released in a work force reduction where I was a Senior Manufacturing Engineer with Infinia Corporation, in Kennewick, WA. I was previously the VP of Production Operations for Omega Systems, Inc. in Phoenix, AZ. I am a well versed Industrial Engineer with expertise in Lean Manufacturing methodologies including 14 years in high/low volume production processes. I have utilized Six Sigma methodologies including establishing quality metrics for validating process capability from prototype production to reproducible/repeatable production after release from R&D/Engineering. I have established multiple production lines from concept to high volume production, improved processes on existing lines using cross functional teams, increased output of existing lines by 50%, improved yield by teaming with sustaining engineers to improve designs, and established assembly improvements through modifications in design and materials.

I have experience (10 years) working closely with engineering in the design phase of a product to establish Design for Manufacturability and ensuring a product can be reproduced with quality and within expectations of a manufacturing environment for low/high volume manufacturing. This includes fixtures, tooling, and automated machinery. I have performed design and manufacturing risk analyses to establish quality plans and method sheets. I have generated Bill of Materials from prototype, performed first article inspections, and been actively involved with establishing the Production Part Approval Process (PPAP) into a quality system. I established a teaming environment for Lean improvements while working for ACSS in an electronics facility. I was responsible for all the manufacturing processes including the hardware used in the product and supplier/vendor relations. We were able to reduce our FGI 83% and still exceed customer expectations in delivery schedule, thus reducing inventory costs using FIFO and single piece flow (demand flow) technology.

I was also involved with a team at Tyco that helped design, build, and institute a 240k sq. ft. production facility in which we relocated and combined two existing manufacturing plants (Pennsylvania and Lubbock, Texas) in a 10 month time frame. We also simultaneously instituted Lean Manufacturing, PPAP and Six Sigma methodology into the production facilities. I have worked closely in a teaming environment with engineering which includes Material Review Boards, Engineering Change Review, configuration management, collaboration in the selection of suppliers, and also with establishing vendor quality standards.

I have six (6) years experience in the semi-conductor and electronics arena to include almost 5 years maintaining gas delivery systems for wafer fabs and training gas system related courses. I have a technical background (18 years) as a Sr. Field Service Engineer (9 years) supporting electro/mechanical systems which includes electronics, solenoids, servos, NiCad storage batteries, hydraulics and pneumatics. I have experience working with ferrous/non-ferrous metals, including identifying material compositions, testing material hardness, high volume automated soldering and joining processes, and wet and dry coatings, including powder coating. I am also familiar with various corrosion control techniques on metals.

I have established safety programs and training and I am familiar with OSHA, NFPA, MSDS requirements and the handling of hazardous chemicals and gases (P&ID drawings). I have extensive experience with military weapon systems including nuclear weapons and their delivery systems and simulator systems. I have managed DOD contracts and ensured compliance with local, state and federal agencies and their regulations. I received Six Sigma Black Belt training. I have experience using AutoCAD, MS suite of programs and Minitab for statistical analysis.

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