CAREER SUMMARY
Work Experience
Ford Motor Company Livonia Transmission Plant
Engineering Specialist - Quality / Aluminum Machining and Main Control Assembly April 2015 to Present
Responsibilities
New Model Launch – Focuses on practices and procedures that adhere to launch cycle plans and timing.
- Work closely with test stand engineers to identify root cause for code reject.
- Focus on QOS and FPS in coaching and supporting adherence to critical standards and continuous improvements.
- Apply engineering principles and analytical techniques to establish and continuously improve manufacturing processes and product.
- Implement interim and permanent corrective actions to resolve quality issues using 8D tool.
- Manage and direct statistical process control activities.
- Execute measurement systems analysis and variable data analysis.
- Identify source of variation within a production environment effectively and efficiently.
- Create OIS and Attachments for 10R Transmission Contamination Specification - Specific Limits and Procedures. Coach Lab Techs on new equipment and process.
- Create quality talks for coaching Utility Floor Inspectors (UFI).
- Coach UFI on the thirteen elements and two levels to become Quality Operation System Coordinators (QOSC).
- Establish tolerance limits and facilitate appropriate corrective action.
- Establish and monitor quality targets levels for each build.
- Provide input for design and assembly concepts which will yield nominal variations.
- Establish critical characteristics for gauging and measuring data collection methods.
- Determine inspection equipment and facility requirements.
- Support expedited concern resolution with cross functional teams including the Quality Department, Production, Suppliers, Manufacturing Engineers (ME) and Product Design (PD)
- Review internal / external suppliers for critical characteristics process compatibility.
GM Corp. – Contract (Aerotek) Warren Tech Center
Quality Reliability Engineer / PPO –BIW November 2013 to April 2015
Responsibilities
- Investigate Weld discrepancies include missing, extra, off location, edge, cold and burn through give direction on repair if required. Contact customer of issue and assist in repair direction.
- Investigate Mix-builds shingling condition, roof and suffix issues
- Investigate damage properties from robotic cells, metal fractures, and workmanship and handling issues. Contact customer on repair direction.
- Worked closely with Engineering (IRT Chair, ME, DE Safety, Validation) to establish a corrective action plan (short/long term).
- Investigate paint, sealer and adhesive issue in the paint shop. Work closely with Paint and Sealer Design Engineers
- Assist in Build Site Direction implementation.
- Review crash condition and design gaps in Vis Mockup. Review part level and GDT in Vis Mockup
- Easel Board reviews
- Investigate and Document Preliminary Root Cause Diamond 1 thru 4. Communicate to customer on quality issues. Weld on weld, mix-match metal, edge welds, sheet metal damage on class A&B surface and Supplier part defects
- Construct Quality Build Alerts (escalation) and review them with operators and tradesman
- Attend Wall/Management review meetings
- Coordinate containment / Respond to stop builds
- Act as liaison between engineering and operations
- Investigate quality and process issue in paint shop that would cover phosphates, elpo, paint and paint shop seal. Work closely with personnel from assemble plants and body shop on issues
1986 to 2013 - International Star Corporation, Chesterfield twp., MI
Quality and Production Supervisor – Tool and Die Designer/Engineer Supervisor – Process Designer/Engineer Supervisor (Automotive and Military)
ACCOMPLISHMENTS
- M28 Liners production – start up
- Thermoforming production lines - start up
- Foam In-Place production start up
- Reduce direct labor below 7% best in company history.
- Reduce die room cost by implementing safety stock number.
- Reduce die room cost by applying comparison studies.
- Reduce PPM by implementing predictive and prevented maintenance on tooling and machinery, also implementing stricter inspection standards and redefine inspection frequency.
- Reduce raw material use by repositioning the product in the material blank.
TEAM MEMBER
Corrective action team - Review all customer complaints (PPR) and defected parts using the 7D of corrective action and 5 Whys, issue a quality alert and correct of action. Audit manufacturing and shipping process, file reports on recommended improvements. Debate ambiguity.
Continuous Improvement Team – Studies ways to improve process by using Five S for Operators, 7 Wastes of Lean Manufacturing.
APQP Team –Participate in step one Pre-Sourcing Activity through step six Feedback, Assessment and corrective Action of the Advanced Product Quality Planning
Safety Team – Review accidents and injuries file reports with recommendation. Educate personnel on lockout / tag out process. Test and certify personnel on lockout / tag out process. Train, test and certify personnel on Hilo. Organize recycling program. Review Material Data Sheets educate personnel on new material hazards
Employee Handbook Committee – Review request from personnel and company negotiate and implement changes to handbook
EXPERIENCE
MANUFACTURING CONTROL
- Develop and control production schedule, which include the scheduling of the raw material for prep and schedule the press setup to run production of finish product to meet customer release requirements.
- Meet with customer account executive and material executive to forecast schedule.
- Train operators on work order instructions and quality inspections
- Review Quality Alerts with operators
PROCESS DESIGN/ENGINEER
- Design and fabricate production lines, work cells that include Fanuc (GMF), Panasonic, Asea robot and IA, that would apply a hot melt adhesive butyl adhesive, silicone or applied seal gasket, Supply new equipment, tooling and test equipment estimates.
- Coordinate all tool design, purchase and fabrication of jigs/fixtures and end effectors (end of arm tooling) for production line and sub-assemble work cells
- Coordinate and control conception drawings to working drawings. Develop timing schedule to track key dates for tooling, process design and product design. Review for ambiguity
- Participate but not limited to Risk Assessments, Preliminary Timing chart, Process Flow Chart, Control Plan, DFMEA, PFMEA, Gage, Tooling, Equipment concept, Run@Rate (GP-9)
TOOL AND DIE DESIGN/ENGINEER
- Coordinate the design and build of tool and die, type of dies were compound dies, hovis master die, and progressive, blanking and steel rule dies.
- Coordinate maintenance or refurbishment on damage tool and dies. Perform preventive and predictive maintenance using MP2 Program
- Oversee all purchasing and returns, for tool and die inventory control and stockroom
- Supply the tool and die estimates and layouts for stamping dies. Die layout would include drawings that show the best material yield. Review for ambiguity.
- Perform full dimensional layout on first shot off tool.
MOLD DESIGN/ENGINEER
- Coordinate the design, and build of production and prototype vacuum thermoform molds used in the GMT and GMX platform in the automotive industry. Environment barrier shield – sound barrier
- Coordinate maintenance or refurbishment on damage molds. Perform preventive and predictive maintenance using MP2 software
- Supply the estimates and layouts for molds. Mold layout would include drawings that show the best material yield. Review for ambiguty
- Perform full dimensional layout on first shot off mold
MILITARY
- Design and fabricate the developments / patterns for military M28 NBC liners, Airlocks, Ammo Clip /Shell chute, bags and end walls. Sewing or thermal heat seal would assemble panels.
- Coordinate quotes for new contract bids for M28 - NBC Liners and Airlocks
- Coordinate working drawings for first article and production of M28 - NBC Liners and Airlocks
DOCUMENT CONTROL
- Control detailed drawing to develop quality control inspection using GDT. GDT to check feature controls profile of surface, profile of line, true position and bead / adhesive placement. Train QAs, Operators, and programmers how to read blueprints.
- Participate in Quality inspection standards and quality documents that would cover the following processes plastic forming, sonic welding, sewing, heat sealing, stamping, and robotic applied seal (foam and silicone)
- Retain test result (peel, break, and inflation). Retain records (QSP, PPAP, tooling, process design and validation).
EDUCATION:
- ITT Technical Institute, Troy, MI
- Associate of Applied Science Degree Computer Drafting and Design Technology
- Technical Career Institute
- Human Relations, Financial Skills (Certificate)
- Oakland University
- Statistical process control (six sigma) (Certificate)
- Pankow Center
- Electronics (Certificate)
STUDIES
Geometric Dimensioning and Tolerance – Planning, Performing and Controlling Projects - Problem Solving – Statistical Process Control/six sigma – Five S for Operators and 7Deadly wastes Lean Manufacturing - Architectural Design and Drafting - Engineering Graphic - Mechanical Design/Engineering and Assembly - Material and Process - Descriptive Geometry - Composition - Digital Information - Technical Graphics – Communication – GIS - Civil Drafting Technology - Design Concepts - Designing with Models - CAD/CAM – Economics by Design
TRADE SKILLS
Jig & Fixture fabrication – Tool & Die Maker - Mold Maker - Fabricator - Machinist – Millwright – Welding (mig, tig, stick and brazing) – Electronics – Sewing - Machine build and Machine repair
SOFTWARE SKILLS
AutoCAD 20006 - Mechanical Desktop 6 – Catia 5 – Adobe Acrobat 3d – Rob CAD – Process Simulate - Microsoft Office -Word - Excel - PowerPoint – Project - MP2 maintenance program - RIP Center - Poster Shop – Soviet – Digital imaging - Photo Shop - Graphic Suite