Engineer Manufacturing

DAVID HALLSTROM

**** ********** ***** *** **, Columbus, IN 47203 269-***-****

qh4s9r@r.postjobfree.com

EDUCATION

MS Industrial Engineering Western Michigan University, Kalamazoo,

MI 1993

BS Mechanical Engineering Cornell University, Ithaca, NY

1985

QUALIFICATIONS & SUMMARY

. Project management for product introduction, process development and

equipment acquisition projects.

. Plant modifications including plant layout, equipment specification &

installation, assembly line balancing, workstation design & layout,

material flow analysis & process improvement.

. Leadership for new product launches and continuous improvement

projects.

. Application of lean manufacturing principles to minimize inventory,

maximize throughput, and optimize facility utilization.

. Cost reduction utilizing value engineering, design analysis, and

process improvement techniques.

. Cost analysis of new products including manufacturing process

determination, machine and tooling selection.

. Process analysis to optimize machine uptime, machine yield, machine

and labor efficiencies.

. Industrial engineering experience in time study, line balancing,

material flow, bottleneck constraint identification, capacity

planning, and manning level requirement determinations.

. Design of assembly, weld and machining fixtures.

. Experienced in APQP activities, including: PPAP, FMEA, Control Plans,

and Flow Diagrams.

. Problem solving using 8D and 5Y techniques for root cause analysis.

. Manufacturing process knowledge includes assembly, CNC machining,

sheet metal forming, plastic injection molding, and induction heat-

treating.

. Implementation of Toyota Production Systems techniques utilizing

Kanban, Poke Yoke, and 5s.

. Skills:

o CNC programming of 4-axis vertical and horizontal machining

centers

o AutoCAD/ AutoCAD lite v.2004

o GD&T and Statistical Tolerancing (RSS)

o Computer-Controlled fastening and torque control systems

o Fanuc CNC/Allen Bradley PLC / Faro CMM

o Lean Manufacturing / Continuous Improvement

o MS Project / MS Office 97

o Process simulation and statistical analysis (SPC)

EXPERIENCE

Rolls-Royce Corporation, Indianapolis IN 10/08

to 05/11

Senior Manufacturing Engineer (Contract Employee)

. Engineering supervisor to support second shift manufacturing of gas

turbine engine components including turbine wheels, compressor wheels,

diffusers and structures.

. Responsible for product and process compliance to FAA standards.

. Troubleshooting of CNC lathes, machining centers, grinding and

polishing operations.

. Directed and authorized product re-work for machining, stamping,

assembly and finishing operations.

. Developed routings and operator instructions for new and existing

products.

Arvin Meritor, Heath, OH 11/07

to 10/08

Senior Manufacturing Engineer

. Project leader of cross-functional teams for an internal plant

consolidation projects.

. Responsible for plant layout, department relocation, equipment

installation.

. Lean manufacturing applications utilizing process improvement and cell

design for throughput optimization.

. CNC Programming of 4-axis vertical and horizontal machining centers.

. Design of assembly, machining and test fixtures.

Douglas Autotech, Bronson, MI 08/05

to 11/07

Advanced Manufacturing Engineer

. Advanced Engineering applications for design & manufacture of

automotive & truck steering columns.

. Cost analysis of new products including manufacturing process

determination, machine& tooling selection.

. Design review to evaluate manufacturability including tolerance

specifications and process selection.

. Coordinate activities with sales, design and purchasing to determine

new product feasibility and cost levels.

. Conducted VA/VE projects for design and manufacturing process

improvement to generate cost reductions.

. Capacity analysis and line balancing for production volume changes and

work cell optimization.

. Tool design of assembly, weld and machining fixtures.

GA Richards Company, Grand Rapids, MI 01/03

to 03/05

Project Engineer (Contract Employee)

. Engineering support for manufacture of office furniture wall panels,

connection covers and corner posts.

. Responsible for CNC programming, sheet metal process development, weld

specification and fixture design.

. Developed process flow charts, control plans, PFMEA's, and work

instructions to support PPAP's for new programs and current

production.

Inductoheat Inc., Madison Heights, MI 03/01

to 03/02

Project Engineer (Contract Employee)

. Project manager for the design and build of induction heating

equipment.

. Responsible for machine concepts, tooling design, and engineering

releases.

. Performed structural design and component integration.

. Managed mechanical, electrical, and control engineering disciplines

for machine design and build.

. Coordinated machine build, tryout, runoff and statistical capability

studies for customer approval.

General Motors Truck Group, Pontiac, MI 11/96 to

11/00

Manufacturing Engineer (Contract Employee)

. Engineering support for process, equipment, tooling, and design

validation of chassis and engine dress for prototype truck vehicles.

. Responsible for the installation and start-up of tooling and equipment

for chassis assembly and engine dress including computer controlled

fastening, hydraulic, and pneumatic assembly tools.

. Participated in design and process validation analysis to assure

product consistency using SPC statistical methods to evaluate fastener

torque.

. Coordinated activities to assess bottlenecks and capacity constraints

using computer simulation modeling.

American Axle and Manufacturing, Detroit, MI 03/96

to 11/96

Industrial Engineer/Project Coordinator (Contract Employee)

. Project coordinator of a (4) four plant cost reduction program

implementing new manufacturing processes, CNC machining and assembly

equipment for the production of automotive axles.

. Developed and maintained project budgets and schedules for capital

expenditures of $50M.

. Engineering analysis including time study, line balancing, material

flow & bottleneck identification.

. Responsible for capacity planning and manning level requirement

determinations.

. Determined process efficiencies, including machine uptime, machine

yield, machine and labor efficiencies.

AFME Inc., Nashville, TN 05/94

to 02/96

Manufacturing Engineer

. Associate to an engineering consulting company conducting productivity

improvement programs for residential windows and heat tape

manufacturing.

. Participated in the implementation of lean manufacturing including the

Toyota Production System, JIT, Demand Flow, and continuous improvement

manufacturing strategies.

. Generated over $2M cost savings by implementing automated assembly

equipment in manufacturing cells based on product and process

commonality.

. Managed the purchase, installation, and start up of injection molding

equipment.

Rockford Powertrain Inc., Rockford, IL 02/92 to

05/94

Senior Manufacturing Engineer

. Project Engineer for a plant modernization program for the production

of drive shafts, u-joints, yokes and clutches for off road vehicle

powertrains.

. Coordinated all activities of equipment procurement including cost

justification, equipment specification, implementation, and surplus

property disposition.

. Implemented manufacturing cells of CNC machining centers and lathes

for productivity improvement.

. Responsible for CNC programming, tool selection, and fixture design.

Clark Equipment Material Handling Company, Lexington, KY 05/90 to

11/91

Senior Manufacturing / Project Engineer

Westinghouse Corporation - Shaw/Walker, Muskegon, MI 07/85

to 05/90

Manufacturing Engineer

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