Manufacturing Project Engineer / IE Manager

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

Cypress CA ***** 951-***-**** ******@*********.***

Steven Bell

Experience 2007-Present Hartwell Corporation Placentia, CA

Senior Manufacturing Engineer

 Developed capital justifications and provided project management for the acquisition and implementation of fabrication and material handling / storage equipment.

 Developed in line de-burring cells to reduce scrap from machine centers.

 Participated in Kaizen and Six Sigma improvement projects in the fabrication and assembly departments as well as root cause analysis for miscellaneous daily issues.

 Improved existing MS Access database for managing Hartwell’s setup and tooling data for 42 numerical control mills and lathes. Integrated database with APS system to automate workflow for new program requests, eliminating overdue shipments attributable to late part program development.

 Updated and maintained facility layout in Autocad. Led several re-layout projects to improve space utilization and operator efficiency.

2006-2007 Leggett & Platt, Inc Cerritos, CA

Division Manufacturing Engineer

 Participated in, and led projects affecting workflow between plants within the Adjustable Bed division, 2 of which were in Kentucky and the Cerritos facility.

 Determined best standard work methods and transferred them to the other facilities. Made extensive use of multi-media techniques to train operators and explain lean-manufacturing concepts.

 Developed Engineering Change workflow application in MS Access to streamline the communication and work processes between the design engineers in Carthage, MO and the plants in Kentucky and Cerritos. The application runs in 3 states in near real-time, utilizes secured electronic signatures and integrates with Outlook. Estimated indirect labor cost savings of $375,000 / year.

 Developed Autocad facility layouts to support various projects in Kentucky and Cerritos, CA.

Plant Superintendent

 Supervised 5 direct reports (department leads and supervisors) and over 120 operators in the robotic welding, powder coating and final assembly processes.

 Participated and led Rapid Continuous Improvement (kaizen) events throughout the manufacturing processes, including assembly line rebalancing and standard work, setup reduction, operator safety, 5-S, and a massive implementation of Kanban pull from assembly back through purchasing. Estimated labor savings of $691,000 / year.

 Developed operator skill matrix to replace seniority as a measure of prioritizing operator retention during downsizing.

 Developed automated performance measurement reporting systems in MS Access.

2000-2006 Interbath, Inc City of Industry, CA

Manager, Manufacturing & Support Services

 Oversaw the Manufacturing Engineering, Configuration Management, Planning, Electronics Assembly, Showerhead Assembly and Packaging Departments.

 Utilized synergy between Configuration Management and Manufacturing Engineering to streamline the product launch process.

 Successfully completed numerous Kaizen projects with small groups. Further reduction in headcount from 30 to 10 operators and reduction in production floor-space from 30,000 square feet to 15,000 square feet. RF sealing machine set up time reduced from 45 minutes to 15 minutes. Estimated labor savings of $500,000 / year.

 Implemented Demand Flow mixed model assembly work cells and an operator certification / evaluation program. Improved linearity to 95% and reduced production headcount from 60 to 30 operators. Estimated labor savings of $750,000 / year.

 Implemented Kanban material replenishment system, resulting in a $2MM inventory reduction (from $10MM to $8MM) and a reduction in warehouse personnel from 6 to 3. Estimated carrying cost savings of $400,000 / year.

 Implemented 5-S housekeeping / visual management at the Interbath Distribution Center.

Manager, Manufacturing Engineering & Project Engineer

 Served as project manager for Interbath’s new Assembly / Distribution center in Walnut, CA. Was in charge of every aspect of the project from the proposal to site evaluation and selection, lease negotiation, contractor oversight & project tracking, permitting, facility layout, workflow / procedure design, developing IT infrastructure requirements and move logistics. The highlight of the project was the design, negotiation, procurement and implementation of a zoned conveyor shipping pick system. The shipping system linked assembly, packaging and shipping into a single flow process. Reduction in shipping headcount from 24 operators to 5 operators. Estimated labor savings of $456,000 / year.

 Supervised the Industrial and Manufacturing engineers and coordinated project schedules and support activities.

 Flowcharted, documented, and streamlined numerous departmental and cross functional business processes.

1997-2000 K&N Engineering Riverside, CA

Manufacturing Project Engineer

 Served as Project Engineer on a 5 facility consolidation into a new 270,000 sq-ft. corporate headquarters in Riverside. The facility consisted of shipping, receiving, a machine / tooling shop with 40 lathes and mills, (2) 50’ long conveyor ovens, 10 injection mold urethane machines, and an open face urethane molding machine.

 Worked with consultants to design and implement in house Enterprise Resource Planning System. Ensured that system supported Demand Flow principles and techniques. Implemented Sales Order sequencing, a process called concurrent assembly sequencing, and computer integrated kanban replenishment.

 Converted 2 main product lines from department to cellular manufacturing arrangements, reducing total product cycle time from 2 weeks to 1.75 hours and staffing from 100 employees / shift to 64 employees / shift. Estimated labor cost savings of $2.2MM/year.

 Participated in numerous kaizen activities to support 30% annual growth rate (Sales were $30MM/year in 1997 and $80MM/year in 2000).

1995-1997 Price Pfister, Inc. Pacoima, CA

Industrial Engineer

 Served on the 2-Handle Focus Factory team which launched fabricated versions of the company’s core product line. This involved a $20 MM retooling and redesign of the machining and assembly processes. Responsible for work / method design in the assembly portion of the focus factory. Specified assembly tooling and material storage. Developed BOMs and routings. 1996 revenue from product line was $100MM.

 Provided leadership and detailed engineering support for a full 7-phase Demand Flow Technology implementation in the 2-Handle Focus Factory and in the implementation of Kanban pull systems in the Pacoima facility and 2 Mexicali facilities. The estimated carrying cost savings from the kanban projects alone were in excess of $2MM/year. Wrote sequence of events using a MTM / computer aided process planning system called EASE, product synchronizations, process maps, sized and designed point of use and in process kanbans. Supervised Industrial Engineering interns in the development of TQC visual instruction sheets.

 Relocated all 5 assembly lines from the focus factory over a 2 month time frame to Price Pfister, Mexicali. All lines were operational at the end of each weekend move.

Education 1990-1995 Cal State Northridge Northridge, CA

 BS, Industrial Engineering.

 Dean’s list, Spring 1994.

Skills

 Proficient in Microsoft Excel, Access, Project, Visio, Power-point, and Word. I’m a developer of Manufacturing and Industrial Engineering related database applications in Access.

 Skilled in Autocad, Cadkey, and some exposure to Solid Modeling.

 Experienced in stopwatch time studies and Pre-Determined time systems

 JD Edwards experience (all PDM modules and World Writer Report Generation)

 Completed training in Leggett & Platt’s internal version of Lean Six Sigma at the Green Belt level.

 Epicor / Avante ERP System

Professional Associations

 Senior Member, Institute of Industrial Engineers

Contact this candidate