Virginia Beach, Virginia, United States
Results-driven Manufacturing Engineer with 15+ years of experience in high-volume automation equipment design, tooling, and process optimization for global manufacturing leaders.
• Develop and optimize new and existing manufacturing processes to ensure successful launch and integration of new products. • Generate process and equipment specification request (RFQ documents, Statement of Work). • Review and update factory equipment standards and ensure proper adherence at system integrators. • Drive equipment and process commissioning on new equipment and production lines by participating in Factory Acceptance Tests (FAT) and Site Acceptance Tests (SAT). • Supporting plant commissioning and start-up. • Lead and participate in equipment design reviews with equipment suppliers and system integrators. • Identify potential equipment suppliers for defined processes. • Participating in development of PFMEA. • Present project status to cross functional members. • Analyze and review designs.
Develop and design full sets of 3D models and drawings for manual, semi-automatic, and automatic manufacturing equipment. • Provide engineering analysis on the design of fixtures, workstations, parts, machines, and processes, including problem identification, analysis, and resolution. • Manage assembly line build and fabrication steps. • Supervise and support the startup of series production of the assembly line. • Research advanced new technologies and develop proposals for automation, mechanization, methods, and special tools for problem resolution and/or cost reduction. • Act as a technical resource for other departments such as Production, Fabrication, and Purchasing. • Conduct risk assessments and safety reviews. • Create PLC programs and interface 3rd party components like vision systems and periphery. • Drive continuous process improvement of existing equipment.
• Develop, evaluate, and improve manufacturing operations related to the machining of crankshafts. • Manage planning, scheduling, testing, and analyses on samples of completed parts. • Provide functional analysis in planning workforce utilization, space requirements, workflow, and design layout of equipment and workspace for maximum efficiency. • Provide strategic guidance for planning with design staff concerning product design to ensure efficient production methods. • Coordinate with vendors to determine product specifications and arrange for purchasing of equipment, materials, or parts, and evaluate products according to specifications and quality standards. • Apply statistical methods to estimate future manufacturing requirements and potential. • Develop designs for fixtures and tools for the Piston/Crankshaft machining process.
Managed a group of 16 machine operators, including hiring, performance review, daily supervision, mentoring, and training. • Ensured process flow, reduced cost, and achieved highest possible customer satisfaction • Reviewed and controlled labor reporting. • Managed equipment efficiencies and created shift/work schedules. • Programmed, set up, installed, and initiated maintenance on all types of manufacturing equipment related to machining of forged parts. • Coordinated with German lead plant for process changes and improvements. • Responsible for programming database for TDS, Tool Dispense System.
Responsible for several high-volume CNC manufacturing lines for diesel and transmission systems. • Programmed CNC-lathe via G-Code, mill, and automation-robotic systems (Sinumerik 840D, Fanuc). • Led tooling cost reduction and process improvements. • Developed and implemented custom tools with tooling suppliers. • Maintained and serviced special technology tools. • Manufactured prototypes and PPAP samples. • Coordinated with Quality department for internal and external quality complaints, root cause analysis, and implementation of corrective actions. • Reviewed customer enquiries, checked producibility, and suggested ideas for cost reductions.