Engineer Project Manager

ROBERT COOKS JR.

**** ****** ****** ****: 513-***-****

Cincinnati, Ohio 45224 Cell: 513-***-****

********@*****.***

SR. LEAN MANUFACTURING ENGINEER

Strong combination of project engineering, lean manufacturing, production readiness, cost reduction and product development experience.

Results-oriented, creative, professional with a proven track record of managing project teams in the areas of new product development, assembly lines development, process improvements and the development of specialized production equipment. Innovative with strong interpersonal skills and over 20 years of experience in the development and manufacture of medical oriented products.

General competencies include:

Project Management Lean Manufacturing (TPS)

New Product Development/Manufacturing Liaison Continuous Improvement (Kaizen)

Assembly Line Process Development Conceptual Design Review

Assembly Equipment & Fixturing Development Production Equipment Development/Runoff

Manufacturing Process Support J.D. EDWARDS

DFMA Production Preparation Process (3P)

Dupont Safety Training Project Capital Planning (ROI)

PFMEA Team Leader/Coach

Cross-Functional Teams

IQ, OQ, PQ for Equipment Cross-Cultural Communications

Design for Assembly

CONTRIBUTIONS & ACHIEVEMENTS

Throughout my career, I have successfully managed many high profile projects and project teams. Lead over 15 continuous improvement teams as kaizen leader and worked with a Chinese manufacturer to set-up production of a critical medical product in China. Trained by Shingijutsu consultants from Japan on Lean Manufacturing and Kaizen over a 3-year period.

Recognized for my ability to work successfully with individuals from diverse functional and cultural backgrounds both foreign and domestic, to form productive work teams.

PROFESSIONAL EXPERIENCE

Staffmark 2009-2011

Cincinnati, Ohio

Contract Manufacturing Engineer

Recruited to help this medical device site with the documentation associated with moving equipment within the plant and from one plant to another. Developing IQ, OQ, and PQ’s , including PM’s for all equipment.

• Developed I.Q. O.Q. and P.Q. protocols to validate machines before and after moving machines. The company later incorporated these protocols as boiler-plates and added them to the quality system of document to be used for future machine moves.

• Developed a new packaging instruction model and presented to management. Management accepted my new model and I was tasked to update all packaging instructions to adhere to the new model. Research and updated the packaging instructions which made packaging much simpler and easy to do. Changed the layout of the packaging area to accommodate this new packaging arrangement. Wrote ECN’s to implement.

• Developed quote packages, sent out the request for quote to potential suppliers to change from make to buy for some in house machined components.

• Develop line layout with power and air requirement for the company’s new Akron, Ohio facility.

• Develop a PM program for equipment used in the new Akron, Ohio facility.

• Key role in the validation of the in house custom cleaning process for custom surgical instruments.

• Develop and wrote standard operating procedures as required.

Hill-Rom Company 1997-2009

Batesville, Indiana

Senior Lean Manufacturing /New Product Development Engineer

Selected as New Product Development Liaison/Project Manager/Team Leader for the Operations division of this major medical products company.

• Lead new product development teams to implement new product on time and under budget.

• Project Leader on multiple $MM dollar projects through the years, managing people, cost, timelines, quality, and the end product out the door and on time.

• Worked as the manufacturing liaison and team leader to set up and manage the outsourcing of one of our product in Xiamen, China. This six months joint venture saved the company one-half mil. per year.

• Developed and implemented “state of the art” flexible paced production lines with mobile positive positioning sub-assembly fixtures for paced line production and transfer of subs to the main line. Managed takt-time/cycle time leveling, tooling, fixturing, contractors and operator training.

• Worked with ergonomics and safety to develop a new employee orientation program that reduced injuries by 25%.

• Developed a patented pneumatic e-ring installation tool that reduced the defects on partially installed e-rings by 40% and reduced the cost of erings usage by $100,000 / year.

• Developed equipment and fixtures for assembly processes, material flow, sub-assembly layout and water spider routes.

• Awarded two patents to date for inventing an assembly aid tool for assembling e-rings and one for my design work on a redesign birthing bed.

• Lead 15 Kaizen Events, eliminating waste and freeing up floorspace throughout the plant and in distribution.

• Cost out leader, managed the reduction of the cost of a product by 10% in 5 months.

Rapid Design Services 1995-1997

Dayton, Ohio

Manufacturing/Process Engineer

Recruited to fill the lead process/manufacturing position for this major automotive company. Responsibilities included developing and managing project Gantt charts for tasks and processes associated with the development and start-up of a new production plant.

• Developed and implemented dielectric coating process for the product.

• Developed production equipment specifications, production equipment and training of operators based on proposed production rates and product specifications.

Mobilite by Invacare 1993-1995

Sanford, Florida

Manufacturing Engineer

Liaison to corporate engineering for new product development for the Respiratory Business Unit of this company. Duties included engineering changes, component part changes, capital equipment improvements and project management.

• Successfully updated and transferred between states, a batch-to-lean production line within a 14-week timeline while staying within budget.

• Developed a product test procedure based on statistical analysis that saved the company $75k and increased throughput by 25%.

Ethicon Endo-Surgery 1990-1993

Cincinnati, Ohio

Manufacturing Engineer/New Product Development

Managed and oversaw technical assignments involved in the evaluation of new product concepts and designs, as well as the development and installation of production processes, production assembly and gage equipment for new product development.

• Directed and managed several contract firms in the design, build and runoff of $2+million in production equipment over a two-year period.

• Designed and managed the successful development of two “state of the art”, $375,000 integrated Staple Maker Loaders utilizing machine vision, eliminating the cost of seven individual workstations.

• Diagnosed and maintained functional production equipment, minimizing downtime.

• Designed and implemented standardized production lines between similar products, minimizing design cost and maximizing production capacity (50%).

EDUCATION/PROFESSIONAL TRAINING

University of Cincinnati Bachelor of Science 1984

Cincinnati, Ohio Mechanical Engineering

Training

Kaizen/Lean Manufacturing Project Management

Kepner-Tregor Good Manufacturing Practices

Coopers & Lybrand Product Development QS9000, QS9001

Manufacturing Statistical Analysis ISO9000, 9001, FDA, UL

Coaching Training AutoCAD, Solid Edge Basic Training

Product Development Cycle Dale Carnegie Training

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