Lean Manufacturing Engineer

SUMMARY

Lean Manufacturing Practitioner with *+ years experience leading a successful lean concept implementation. Creative hands-on self-starter with 20+ years of high volume manufacturing and engineering experience. Noted professional presentation abilities coupled with exceptional oral, written and interpersonal communication skills. Recognized as a change agent with a record of being able to establish, communicate and execute a vision in a way that mobilizes others to share the passion. Proven ability to lead and influence with or without authority. Major accomplishments and strengths include:

• Outstanding Technical Ability: Advanced problem solving skills and analytical abilities, derived from 20+ years of servicing complex computerized manufacturing systems incorporating the following technologies: electronics/electrical systems, high voltage, RF systems, rough and high vacuum systems, robotics systems, electro-mechanical systems, pneumatic systems etc. Implemented safe, cost effective, pit-stop style PM’s.

• Responsible Project Management: Successfully coordinate, support, schedule and complete multi-disciplinary projects. Resourceful in diagnosing, researching and finding effective and clearly communicated solutions to customer-specific requirements. Ability to gather, analyze and summarize data to draw rational, fact-based conclusions.

• Uniquely diverse range of skills: Proven lean change management skills implementing lean manufacturing improvements at all levels of the organization (factory workers to factory manager). Able to achieve breakthrough results by analyzing data from various perspectives to develop and implement comprehensive action plans. Excellent communication, human relations, and cross-functional team building skills along with accomplishments in leading, motivating, and developing co-workers.

EXPERIENCE

Factory Equipment Engineer Aug 2008 – May 2009 MA/COM, Lowell, Ma

• Maintained semi-conductor factory equipment uptime and availability including planned maintenance scheduling, equipment upgrades, and continuous improvements in order to insure customer lead times were always met or exceeded.

• Updated planned maintenance scheduling of 300 pieces of equipment to only include effective PM’s thereby providing a decrease of 20% in the number of PM’s scheduled per week, mitigating production interruptions.

• Upgraded the SSEC Metal Lift-Off system robot in order to automate processes that were done manually which lead to a 25% decrease in cycle time for the Metal Lift-Off area.

• Lead a cross functional PM focus team that included Equipment Engineering Technicians, Manufacturing Technicians, Process Engineers, and Factory Management using observation, advanced problem solving techniques, and scientific method resulting in a PM performance against schedule improvement from 50% to an average of > 98%

• Mentored maintenance technicians in advanced problem solving and root cause analysis which lead to an overall equipment availability improvement from 85% to >92%.

Senior Reliability Engineer Dec 2007 – Aug 2008 TEL Epion, Billerica, Ma

• Managed the Gas Cluster Ion Beam platform move from R&D to a semi-conductor production worthy state for .22 nanometer geometries that will meet customer process requirements and for the following: defect levels, overall quality, MTBF and OEE.

• Extended GCIB electron gun life from <100 hours to >500 hours by improving rebuild quality and repeatability.

• Developed work instructions for testing assemblies after installation in order to insure operability prior to vacuum pump down leading to zero reworks following PM activities.

• Characterized assemblies and subassemblies to determine components planned maintenance intervals in order to maximize output without compromising quality.

• Designed test plans followed by action plans that decreased wafer defects by 50%

• Interfaced with a parts cleaning vendor to validate and improve cleaning procedures leading to a 100% improvement in GCIB parts reliability.

EXPERIENCE (Continued)

Lean Implementation Engineer 2002 – 2007 Intel Massachusetts, (F17) Hudson, MA

• Drove lean culture change through all levels of the organization by embracing continuous improvement via systematic small-and-rapid learning cycles until 100% of the organization embraces continuous improvement and waste elimination as the only way to do business.

• Addressed factory constraints with creative solutions by teaching advanced lean methods and leveraging the skills of those doing the work.

• Lead an equipment restoration project from start to finish on a fleet of 15 Endura HDP Thin Films Processing systems, which included training 24 technicians across 4 shifts and scheduling restoration activities in such a way that production was not impacted. Project resulted in a sustainable improvement in equipment availability of 15%.

• Improved factory equipment availability average ~20%, from ~70% to ~90%, using Standardized Work and Total Productive Maintenance projects throughout the factory.

• Drove 50% lead time reduction from ~90 days to ~45 days via waste elimination line balancing, equipment stabilization and Inventory (WIP) Reduction programs.

Thin Films Operations Group Leader 1998 – 2002 Intel Massachusetts, (F17) Hudson, MA

• Lead a 15 person team, tasked with meeting all customer requirements via operations goaling, equipment and maintenance scheduling, to a 100% on-time delivery record.

• Trained employees on operation, repair, and preventive maintenance standards in regards to safety, quality, output and technical specifications for equipment resulting in zero safety and quality incidents.

• Lead equipment planned maintenance improvement projects using SMED techniques providing a 20% reduction in PM green to green times providing improved production capabilities.

• Worked as Factory Shift Manager when the shift manager & staff were off shift for any reason. The job details included: managing 150 technicians to meet or exceed factory safety, quality, and output shift metrics.

Equipment Engineer 1989 – 1998 Digital Equipment Corporation (F6) Hudson, MA

• Project manager, equipment engineer and process engineer, for WCVD (Tungsten) fleet of thin films deposition equipment.

• Optimized equipment insitu cleaning regimen thereby increasing the time between PM’s by 15%.

• Upgraded all MFC’s to metal seals which provided for a 10% reduction in wafer defect levels.

• Provided leadership and trained equipment technicians on planned maintenance, troubleshooting and repair of equipment to obviate the need for OEM contracts to maintain equipment leading to a savings of >$100,000 per year.

EDUCATION

Southern Illinois University, Carbondale, IL. BSOE

Japanese Institute of Plant Maintenance, Tokyo, TPM leader course

Lean Learning Center, Novi, Mi. 40 hour Lean Experience course

USN, Great Lakes/Groton Sub-Base, Electronic Technician A, B & C Schools

USN, Groton Sub-Base, Instructor Technical Trainer, 160 hour Course.

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