Engineering Professional

Charles A. Smith, CPIM

**** ****** **** **, *****, Alabama 35971

Home: (256) 623 - 2047 Cell: (615) 517 - 4443

****************@*****.*** or ****************@*****.***

Note: Work experience is in reverse chronological order under experience heading and I was employed in more than one job at some places.

Experience in the areas of Industrial/Quality Engineering, Safety or Supply Chain Management

• Quality Specialist - Failure Verification Lab @ Dell, Inc., Lebanon, Tennessee (2004 - 2007): Process I developed: 1). Collect timely defect data and record the numerous attributes in columns on an Excel spreadsheet. 2a). Based on overall part usage for the same time period I would calculate Defects per Million (DPM). From this data I would use the Pivot Table function of Excel for Pareto Analysis, to investigate trends and for comparison studies. 2b). Determine the cost of each defect and multiply cost by frequency. Sort the results - similar to ABC Analysis. Larger values were usually unique and accountable and smaller values were normally random and uncontrollable. 3). Review results of steps 2a) and 2b) to determine priority and investigated. From my investigation I would determine root cause, corrective action and party responsible for corrective action. I would follow-up to make sure the cause did not re-occur. Results Detailed on Page 3. Results: $2,000,000+ saved.

• Engineering Technician/Specialist - Failure Verification Lab @ Dell, Inc., Lebanon, Tennessee

(2001 - 2004): Ordered equipment and performed assembly/troubleshooting of computers to inspect, repair and test microprocessors on a daily basis. These parts were damaged in production; some were salvageable and some were not. Results: $6,000,000+ saved.

Based on a proven need, determined from interviewing & investigation, I conceived and implemented an inspection process in the Cancelled Order Disassembly area to prevent damaged microprocessors from returning to the production line; these parts were repaired or disposed of. Results: $500,000+ saved.

I also created ‘5S’ guidelines for the lab, hired a cleaning crew to clean the lab and inspected the lab for violations. I also maintained power and network connectivity to the lab. I maintained a ‘dwell inventory’ in the lab, on damaged parts awaiting investigation, of less than six days.

• Occupational Safety Specialist @ Tennessee OSHA, Nashville, Tennessee (1992 - 1993): I performed successful safety inspections of construction and industrial sites which included: 1) an Opening Conference - to inform the company representative(s) of the reason for the visit and their legal rights and responsibilities 2). Walk Around - to inspect the site for safety hazards and 3). A Closing Conference - where I informed the company representative(s) of any safety hazards I discovered and the proposed citations to be issued at a later date by our office. I also inspected injury rates and safety programs while at the company’s site.

On the days in the office I would write up the citations for processing. Also, while in the office, I would answer safety questions called into the office by phone.

• Industrial Engineering Analyst @ Boeing - Georgia, Inc., Macon, Georgia (1988 - 1989): Investigated the cause of defects using Pareto and other forms of analysis. Generated forms. Improved fixture designs by changing from wood to metal and adding functions. Successful cost justification studies for ordering of additional equipment. Improved the functional plant layout in the rib assembly department. Other minor duties of a technical nature. Member of the Total Quality Management team.

Experience in the area of Computer Technology

• Electro-mechanical Repair Technician and Electro-mechanical Repair Senior Technician @ Dell Computer (later changed to Dell, Inc.), Lebanon, Tennessee (1999 - 2001): I performed troubleshooting on personal computers using: 1). Dell Diagnostics 2). Peripheral Diagnostics e.g. from a floppy disk 3). Using the isolation, or ‘strip down’, method or 4). Using reference manuals based on led lights or beep codes.

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(Charles A. Smith continued from page 1.)

I performed successful repair on personal computers by: 1). Replacing defective hardware e.g. motherboard, hard drive, etc. 2). Adjusting one, or more, of the CMOS settings 3). Adjusting Operating System parameters or 4). Reloading software.

Also, I connected peripherals cabling to a personal computer; I would adjust settings to make them operational. I was trained to use Electrostatic Discharge protection to prevent shock damage, or degeneration, to hardware.

Experience in the area of Mechanical Technology

• Maintenance @ Grand Old Golf, Nashville, Tennessee (1996 - 1997, 1998): Successful repair of engines and prop assemblies used on bumper boats. Trained employees to operate boat rides. Other successful repairs in carpentry, masonry, electrical, plumbing and irrigation. Design of wood enclosures, covers and shelving.

• Special Machine Building and Process Engineering Technician for Manpower, Inc., Nashville, Tennessee (1993 - 1995): successfully assembled ‘Special Purpose’ automated machinery from blueprints and schematics. Documented defects in glass production by cutting them out of glass samples using a glass cutter.

• Maintenance Technician @ State Industries, Ashland City, Tennessee (1991 - 1992): repair of industrial equipment by replacing electrical motors, chains, gear boxes, etc. Arc welding for construction and repair.

• Engineering Services Supervisor (and AutoCAD Design/Draftsman) @ Campbell Hausfeld, Mount Juliet, Tennessee (1990 - 1991): successful mechanical drawing designs and changes using AutoCAD software.

• Bench and Jig Assembler and Assembly Inspector @ Textron Aerostructures (formerly AVCO), Nashville, Tennessee (1984 - 1988): precision drilling and grinding of aircraft parts for assembly. Installed specialized fasteners. Used blueprints and plan books. | As an Inspector I inspected aircraft assembly work performed by others. I either signed off the steps as completed or documented discrepancies in the Non-conforming Material (NMR) process for the purposes of engineering review and corrective action.

Education

• Middle Tennessee State University (MTSU), Murfreesboro, Tennessee (1981). Bachelor of Science degree. Major: Industrial Technology Minor: Math 3.23/4.0 average. Graduated in top 20%.

• Nashville State Technical Institute (now Nashville State Community College), Nashville, Tennessee. Associates of Applied Science degrees. Two majors: Mechanical Engineering Technology (1990) and Computer Technology (1999). 3.8/4.0 average both times. Graduated with ‘Highest’ honors both times. [I attended Nashville Tech after graduation from MTSU - mainly to acquire some additional hands-on skills]

• OSHA Institute, Des Plaines (Chicago), Illinois. Initial Course for Safety Compliance Officers (1992).

Awards and Certifications

• Certified in Production and Inventory Management (CPIM-APICS). Passed exams in all 5 modules - these exams test logic and decision making ability as well as knowledge of subject matter (2009)

• Winning Culture Award and 4 Silver Stars. (Dell, Inc.) (2002 - 2006).

• Green Belt Training & Certification. (Dell, Inc.) (2004).

• A+ Certification (Computer Technology Industry Association) (1999)

Computer Skills

• Microsoft Office - Excel, Word, Outlook and Power Point. AutoDesk AutoCAD

• Inventory software like Glovia, MIS and others.

• Microsoft Operating Systems - Windows 95, 98, ME, NT, 2K Pro and XP.

• Classroom training in DOS and UNIX.

• Classroom training in CNC and PLC programming.

Quality Specialist Results - from page 1:

(These results were initiated from Excel spreadsheets – usually from filtering or by running pivot tables)

Example 1

I noticed a very high DPM (Defects per Million) rate on dropped hard drives from one of our suppliers. (Dropped parts, especially hard drives, were automatically scrapped). I went to the production area where these drops were occurring and investigated the matter further. I noticed that the packaging around these hard drives was tight making the product difficult to remove from the packaging. I concluded that the production associate was pulling the whole box off of the shelf trying to ‘pick’ the part.

I constructed a gripping device and used a force gauge to measure the removal force required. I compared it to hard drives packaged by other suppliers and found the removal force to be 9 times that of other suppliers. I reported my findings, in detail, to my Quality Manager and the Dell Safety Manager. My results further supported the efforts of a Safety Engineer, in the home office, that was working on the same problem. The problem was then assigned to the engineer in charge of supplier packaging. The packaging was scheduled to be changed. I was laid off before this was finalized.

Example 2

I observed a very high DPM (Defects per Million) rate on damaged connectors on hard drives from one of our suppliers. Myself, and the Material Review Board Associate, suspected that these connectors were being damaged by the supplier representative that was assigned to test these parts in our on-site Failure Verification Lab. The supplier representative was dispositioning the parts as if the damage was occurring on Dell’s production line. i.e. Dell had to pay for them.

To build a case I took photographs of the connectors on the hard drives prior to the supplier representative testing them. I performed this action on second shift. I saved these photographs by hard drive serial number. I then took the same photographs on the same drives after the supplier representative tested them. I did, in fact, prove that the supplier representative was damaging the hard drives in the course of conducting the test. I sent my report to my manager. The abnormal amount of connector damage coming from this supplier was stopped and never reoccurred during the course of my employment there. I helped stop damage from other suppliers by repeating a similar process.

Example 3

On my Excel spreadsheet I observed a high incidence of memory modules being failed for scratches on the gold contacts. The supplier representative dispositioned these parts as being damaged in Dell’s production process. This meant a scrap loss for Dell. From my experience as a computer repair technician I knew these were normal insertion marks. I consulted with one of Dell’s Supplier Quality Engineers on this matter. He agreed with me and the supplier representative stopped dispositioning these parts as Dell Induced Damage. There is no way to calculate how much this measure saved Dell.

Example 4

I monitored parts dropped in the production area on a daily basis. I not only monitored Defects per Million, but I also looked to see how much Dell paid for each part. High end video cards, for example, cost about 20 times that of the standard video card. I would send an alert to the Production Manager, or immediately investigate the root cause myself, if abnormal quantities of high dollar items were suddenly being damaged.

These are just a few of the examples of my contributions in the course of my employment as a Quality Specialist. Since my approach, and solution, to each problem was normally unique I have not figured a way to communicate this in brevity.

My job as a Quality Specialist, and Engineering/Technician Specialist, involved more Loss Prevention than anything else. The measures that I helped put in place not only fixed the immediate problem, but set legal and technical precedent for future control measures. Most of my efforts also involved a great deal of discretion.

Key Words: Six Sigma, Lean Manufacturing, CPIM, A+ Certified, Computerized Numerical Control, CNC, Programmable Logic Controllers, PLC, AutoCAD, Microsoft Office Suite, OSHA, On-The-Job Training, Project Management, Glovia, MIS, Excel, Pivot Tables, ISO 9001, ISO14000, PLC, blueprints, schematics, BOMs,IT.

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