Engineer Manager

Edward G. Duncan

**** ********* *****

Gainesville, Georgia 30506

678-***-**** (H)

404-***-**** Cell

Objective: To associate with a progressive engineering /manufacturing firm as an Engineering/Project Manager, with an opportunity to advance to Upper Management.

Key strengths: A creative, action-oriented, engineering professional, which has consistently decreased costs and increased productivity. Ability to process thoughts logically, to observe, listen, and provide solutions. Also, I have the willingness to take responsibility for a project, set challenging goals, and lead a team in meeting those goals.

• Six Sigma Green/Black Belt

• Lean Manufacturing (Value mapping, 5S, Kanban, Visual Work Shop)

• Project / Engineering Management

• Kaizen / DOE / FEMA / Poka-Yoke/DFM-DFA

• AS/Q1 / ISO / QS9000 & ISO 1400/ASME/FDA

• TQM / APQP

• Capital Project Management

• Metal – Hydro-forming, Welding, Machine Forming & Roll Forming, Casting

• High Precision CNC Machining

Work Experience:

Sr. Operations Manager. EMS-Technologies, Norcross, Ga. 2008 to present.

As an operations manager for this $335M dollar supplier of wireless and microwave based communications for defense, commercial and space applications.

• Resolved Brazing issues by conducting vendor on-site DOE that improved defect rate from 25% to 5%. Cost savings of $150K to the program.

• Conducted advanced laser cutting process trials for “thin layer” cutting for missile seeking program than resulted in a $1.7M capital cost reduction.

• Developed relationship with metal casting house to fabricate RF “horns” that resulted in a $280K cost reduction to the program.

• Determined best practices for plating of plastics; located second source vendor that improved quality and delivery of plated parts by 30%.

• Worked with Stepper Motor supplier to resolve water/icing issues. Conducted on-site assembly trials with alterative sealing option resulting in an improved performance and delivery by 28%.

• Conducted SMED event to reduce tooling changeover times which resulted in $318K cost savings.

• Introduced TPM program to operational shop floor that has decreased down time by 8%.

• Created Maintenance Department – this includes hiring and managing this group.

• Determined the need to order 80% of raw stock in pre-cut form net savings in labor approx. $100K

• Managed shop work schedule which improved throughput by 26% a $450K cost avoidance by reducing the amount of outsourced CNC machining work.

• Optimized machine/labor usage by using multi-tool set-ups creating a 2:1 ratio of machines to operators a 20% increase in productivity.

• Introduced 5s principles to machine shop with monthly auditing.

• Determined true Make vs. Buy calculations for all Metal fabricated parts.

• Arranged Six Sigma Green Belt training for all Manufacturing Engineers (SQA certification).

• Developed four distinct focus factories for key products to maximize capital utilization and improved product launches by having focused teams.

• Standardized the Internal Kaizen process by creating a useful document package to capture the events improvements.

• Deployed cellular work cells to improve work flow and product throughput.

• Released Manufacturing Readiness Review format using APQP techniques.

• Manufacturing engineering team has coordinated or conducted $850K cost savings avoidance events in 2010..

• Introduced lean tools such as Value Stream Mapping, Point of Use Inventory, FMEA, Flow diagrams, SMED, Visual Work shop and 5s Tools.

• Provided standardized ROI format for capital requests that is measurable for the expenditure.

Manager of Manufacturing Engineering Chart Industries, Canton, Ga. 2005 – 2008.

As a Manager of Manufacturing Engineering for this supplier of cryogenic cylinders to the medical, beverage and liquid gas industries:

• Decreased welding costs by installing weld inspection laser vision system.

• Redesign soldering machines with controls that depend on less operator interface.

• Improved Vacuum manifold technology with advanced process controls.

• Supervised the projects and workload of staff engineers.

• Developed Adaptive welding systems for circumferential welding machines.

• Implemented training for Lean Concepts.

• Designed and built new welding equipment to improve weld quality and production.

• Created the internal structure for process engineering document control.

• Assisted in plant consolidation for China facility.

• Introduced resistance welding to increase through-put and quality.

Interim Plant Manager American BOA (IWKA Co.), Cumming, Ga. 2003-2004.

As a Plant Manager: This Position was only on an Interim bases while the current manager was away opening a new plant.

• Increased production out-put through reorganization of equipment.

• Identified bottlenecks in production by doing a capacity planning review.

Manager of Manufacturing Engineering American BOA (IWKA Co.), Cumming, Ga. 2001-2004.

As a Manager of Process Engineering for this tier one/two automotive exhaust components supplier:

• Managed multi-million dollar capital projects.

• Negotiated contracts for capital projects.

• Supervise the workload of six staff engineers.

• Developed robotic weld applications.

• Directed continuous improvement projects for current manufacturing activities.

• Established budget needs for capital and continuous improvement projects.

• Assisted in start-up of new production plant in South Africa.

Sr. Manufacturing Engineer American BOA (a Div. Of IWKA), Cumming, Ga. 1998-2001.

As a Sr. Manufacturing Engineer for this tier one/two automotive exhaust components supplier:

• Reduced bellows Hydro-forming machine down time from 40% to < than 10%.

• Piloted a program to reduce tooling costs and material scrap rate for plant tube mills a cost saving annually of $450K.

• APQP team leader to introduce single stage hydro-forming for rapid prototyping.

• Implemented first companywide robotic product assembly line; program cost savings $840K

• Launched a program to introduce tube form parts vs. deep drawn; program cost savings of $2 million.

Sr. Design Engineer Zellerbach (a Div. of Mead), Marietta, Georgia 1997-1998. As a Design Engineer for this multi-million dollar manufacturer of plastic film for consumer product packaging industries:

• Designed tool and die for new plastic film stand-up pouch called Zflex.

• Worked with manufacturing on assembly and start up of first prototype machine.

• Coordinated with outside vendors on the purchasing of component and manufactured parts for tooling and machine assembly.

• Developed servomotor application for die cutting operation on film sub-straight.

Design Engineer Walton Stout Inc., Lithonia, Georgia 1996. As a Design Engineer for this manufacturer of bulk handling systems for plastic and glass industries:

• Designed gravity feed material containers.

• Specified the sizing of conveyors--gravity feed chute and elevators.

• Coordinated field installation of equipment.

• Interfaced directly with manufacturing on best method to produce product.

Design Engineer Andersen 2000 Inc., Peachtree City, Georgia, 1995-1996. As a Design Engineer for this $20,000,000 manufacturer of incinerary devices for the disposal of medical and solid waste products:

• Redesigned drag conveyors-reduced assembly time in construction of conveyors.

• Created two-ton waste product hydraulic lift and rail system.

• Identified problems on hydraulic lift for product disposal-resolved design problems.

• Collaborated on design for an incinerary burner pressure vessel and its weather shield.

Design Engineer Nordson Corporation, Atlanta, Georgia, 1983--1995. As an Applications/Design Engineer for this $500,000,000 manufacturer of product assembly equipment for the non-woven and packaging industry:

• Lead manufacturing teams on various product rollouts.

• Wrote procedures for ISO 9000: candidate for internal auditor.

• Member of Engineering Standards Review committee.

• Worked with electrical, hydraulic, and pneumatic systems.

• Interfaced directly with customers on product development.

Awards and Accomplishment

• President's Award -- For helping department meeting its goal of capturing

50% market share in Nonwovens product assembly.

• Patent -- For disclosing Preset Orbiting Spray Nozzle (Reduced customer down time

• Patent –(International) Inner tool design to stabilize flexible hoses during assembly

• Member of the Society of Manufacturing Engineers.

• Member of the American Welding Society.

• Security Clearance Level 2

Education

MS, Engineering Management, Eastern Michigan University (attending)

BS, Industrial Management, Georgia State University

BS, Industrial Engineering, Georgia Institute of Technology

AS, Industrial Engineering, DeKalb College

AS, Mechanical Design, ETI School of Drafting & Design

Six Sigma Training Green/Black Belt, Villanova University

Certificates: Lean Manufacturing, Georgia Institute of Technology

Weld Analysis Gas Metal & Flux Cored Arc, DaimlerChrysler

Root Cause Analysis Workshop, Euro-Quest

Hydro-forming Technologies, Society of Manufacturing Engineers

Stainless Steel Tube & Pipe Production, Tube & Pipe Association

Failure Mode Effect Analysis, Georgia Institute of Technology

Total Quality Production Systems, IWKA

MS Project, CompUSA

Basic Vacuum Practice, Varian Industries

Automation Weld Training, Miller Incorporated

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