Plant/Manufacturing/Quality Engineering
Resume:
GLEN A. RAWLINGS, BSME, MSA
Madison Heights, MI 48071
*************@*****.***
HIGHLIGHTS OF QUALIFICATIONS
• Seventeen (17) years progressive experience in manufacturing including: Plant Management, Operations Management, Manufacturing Engineering Management, and Program Management
• Strong balance of interpersonal and motivational skills, engineering application, and business management.
• Successful implementation of Lean Manufacturing Processes through lean principles (one piece flow, U-shape assembly), and leading Kaizen events.
• Product development and Design-for-Manufacturing skills applied across a wide variety of products from interior headliners and doors, to automotive drive-line and sunroof systems.
• Strong understanding of the critical relationship between product planning, development, product phase development, design for manufacturing, and the timely involvement of assembly operations in product development.
• Ability to effectively manage suppliers to attain desired quality levels through disciplined process analysis (control plans, PFMEA’s, root-cause analysis)
• Strong direct customer interface and relationship building skills. Frequent interface with customer quality and resident engineering personnel.
• Extensive project management experience with large capital equipment projects.
EDUCATION
1999 - 2002 MASTER OF SCIENCE ADMINISTRATION (MSA)
Central Michigan University
1988 - 1993 BACHELOR OF SCIENCE IN MECHANICAL ENGINEERING (BSME)
MANUFACTURING CONCENTRATION
Lawrence Technological University, Southfield, Michigan
WORK EXPERIENCE
Company Confidential
Oct.04 – Present Plant Manager
• Reporting directly to the VP of Michigan Operations.
• Immediate direct reports include: Materials Manager, Quality Manager, two (2) Assembly Managers (1st/2nd shift), Maintenance Manager, Master Black Belt, Black Belt, Program Managers, Quality Engineers (3), and Manufacturing Engineers (3).
• Responsible for safety, quality, productivity and delivery of approx. 800,000 units produced in two (2) facilities by a non-union workforce of 300+.
• Implemented OEE tracking system site-wide by assembly line (nine total) to effectively track: Uptime, Downtime, Scrap, and throughput based on bottle-neck cycle time. Effective use of line balancing to match customer Takt.
• Production scheduling of labor, materials and maintenance personnel based on customer 12-week forecast.
• Standardized production reporting process through daily stand-up meeting
(line-side) to review prior day production results.
• Personal measures include: Labor as % of sales, Inventory turns, Safety Recordable (incidents), Quality PPM rating, Internal PPM rating, Schedule attainment to build requirements, Continuous improvement savings.
• Annual budget development: Direct/Indirect Labor, capital investment budgets, sundry account development (quarterly expeditures)
Manufacturing Engineering Manager
• Direct supervision of ten (10) degreed engineers: Controls and Mechanical and Industrial.
• Development of equipment specifications focusing on standardized use of components (reducing MRO inventory), controls structures and ergonomics.
• Capital budget development for machine improvements/upgrades.
• Implemented Lean Manufacturing Principles, conducting line balances to optimize material flow toward one (1) pc., eliminating bottlenecks.
• Coordinated the release of product changes to assembly operations, ensuring timely preparation of the assembly line, well balanced processing rates (work balance). Implemented machine poka-yokes, and material pack-out systems.
• Direct interface with product engineering in the development of new modules, focusing on Design for Manufacturing principles.
• Conduct root-cause analysis of rejected materials using Red X philosophy, and applying Green Belt training using structured DMAIC steps.
June 03- Oct.04 PLANT PROGRAM MANAGEMENT
MANUFACTURING ENGINEERING SUPPORT
JOHNSON CONTROLS - ASG, INC.
• Received program following phase two (2) of six (6) phase process. Working with purchasing and product engineering, initiated Development phase “design freeze” and kick-off of production tooling. Establish prototype control plan and selection of prototype suppliers. Coordinate bill-of-material (BOM) development with product engineering.
• Monitor tooling development and supplier launch readiness.
• Review supplier APQP compliance: Control plans, PFMEA’s, work instructions and supply chain management structure. Apply prior lessons learned.
Production Preparation Phase:
• Develop launch planning timelines for weekly management review, identifying ‘at-risk’ items and coordinating actions to return to target schedule.
• Coordinate with advanced manufacturing engineering on capacity requirements, customer specific processing requirements, part tracability, poka-yokes, and timing of prototype parts. Identify customer key characteristics for gaging and SPC tracking as required. Ensure process meets capability and capacity requirements.
• Attend weekly meeting with purchasing and product engineering ensuring customer performance requirements are fulfilled, tested and validated in-line with launch requirements and ready for phase sign-off..
• Participate in new equipment run-at-rate testing and sign-off.
• Attend customer plant level launch meetings on timing and customer requirements pertaining to material sequencing, container requirements, packaging and labeling.
• Serve as direct contact with customer plant (DCX SHAP) for timing and quality related issues as a result of launch activities, as well as current level model issues.
• Participated in VA/VE events at customer facility on DCX door program.
Launch Phase:
• Ensure supplier PPAP submissions are complete (or authorize Interim Approval as required) along with corrective action plans and timing to resolve Interim status.
• Develop launch planning timelines for new model launches
• Coordinated planning meeting with plant level manufacturing engineers to improve cost measurables on current level production.
• Provide direct customer support at the plant level (SHAP) for production trial runs and quality related issues (DCX Door and Overhead systems)
• Supported startup initiatives and run-at-rate approvals at Van Buren and customer plant (Orangeville).
• Managed carryover model launches at the plant level on part level changes.
Jan.00 – Jun.03 MANUFACTURING ENGINEERING MANAGER
AMERICAN AXLE & MANUFACTURING, INC.
• Direct supervision of eleven (11) salary degreed engineers: Controls, Manufacturing, and Industrial.
• Managed the design, development, integration and launch of assembly systems for new GM programs (GM H2/610, GMT360/370), as well as the upgrade of existing assembly equipment for GMT800 platform.
• Managed product program changes throughout two (2) assembly facilities relating to four (4) separate GM programs. (ie. Machining changes, component revisions)
• Managed continuous improvement activities relating to OEE /FTQ/Productivity Improvement Plans.
• Generated projects for funding machine improvements and new equipment (insourcing operations).
• Managed engineering department budget for overtime, salary allowance, as well as project funding.
Progam Management /Productivity Manager (1-1/2 yrs)
AMERICAN AXLE & MANUFACTURING, INC.
• Program delivery team member. Coordinate launch readiness, monitoring and tracking program deliverables. Coordinate weekly meetings regarding customer requirements, PPAP status, launch readiness: Production Equipment, Materials, APQP documentation.
• Launch multiple assembly line automatic stations in support of customer requirements: Automatic oil fill systems (2), automatic air test systems, robotic unload and press operations (2), automatic bolt feeding and DC torque systems. a
• Coordinate layout improvements for reduced cycle time and material handling.
• Provide cost/benefit analysis for future programs (ie. Make vs. buy)
• Coordinate the release of new level materials to production based on customer timing requirements. Coordinate the flow of PPAP materials from supplier facilities, ensuring the controlled introduction of material into production for production-trial runs (PTR)
• Developed capital equipment proposals for plant expansions
Sept.98 – Jan.00 SR. MANUFACTURING ENGINEER
AMERICAN SUNROOF CORPORATION, LIVONIA, MI.
• Process improvements in automotive paint facility
• Supervise two (2) salary engineers and eight (8) maintenance personnel
• Compliance with QS9000 requirements including: Updating PFMEA’s, controls plans, process flow diagrams, etc.
• Liaison with GM & Daimler Chrysler product engineers
• Make vs. Buy analysis
• Drive quality, safety, throughput, and cost reduction initiatives
Sept.92 – Sept.98 PROCESS ENGINEER
FORD MOTOR COMPANY, WINDSOR, ONTARIO
• Aluminum cylinder head casting operations – 950,000 annual volume
• Responsible for all process engineering issues relating to quality, throughput, and machine upgrades in casting and core production department (I-4/V6/V8/V10)
• Oversee installation and launch of $3 Million automated casting cell incorporating robot automation and major conveyor rearrangements (continuous and power and free)
MAINTENANCE SUPERVISOR (1.5 YRS)
• Direct supervision of twenty-five (25) union skilled trades personnel of various disciplines (continuous three (3) shift rotation)
PRODUCTION SUPERVISOR (1.0 YR)
• Direct supervision of thirty (30) union production personnel (continuous three (3) shift rotation)
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