SUMMARY
Creative, organized Management and Senior Engineering professional with significant experience managing people and improving processes in the metals manufacturing industry. Special expertise includes cost improvement strategies, implementation, productivity, work design, and project management. Open objective management style that leads by example, honesty, and clear communication.
Strong record of documented success and demonstrated strengths in:
• Lean Manufacturing • ISO 9001-2008
• Plant productivity and optimization • Design of fixtures, jigs and shop floor aids.
• SPC, FMEA, DFMA • Waste and cost reduction techniques
• Project Management • Solid Works, AutoCAD and Pro-E drafting platforms
• Metal fabrication processes, S/Metal, CNC Machining, etc.
• Cellular plant layout design • Process design and improvement
• Tooling design
PROFESSIONAL EXPERIENCE
STEWART & STEVENSON LLC, Start up Facility, Killeen/Fort Hood, TX 2012- 2013
Senior Industrial Engineer
In charge of all Industrial Engineering areas, time and motion studies, line balancing, operations research matrix to optimize assembly, improve ergonomics, BOM, routings, recommended purchase equipment, designed tools to run parts on CNC lathes, responsible for ECN’s, lean manufacturing improvements, labor efficiency & productivity, and responsible for supervising the maintenance employees.
• Documented and created visual aids and work instructions of the whole tear down process of the trucks from complete all the way to the chassis, at the same time guiding and helping the operators in the assembly process, reducing re-work and quality defects to zero, and minimizing labor cost, and waste.
• Reduced walking waste distance by 20%, by designing a layout in AutoCAD that compressed all areas among all departments on the shop floor, and at the same time generating enough extra floor space to create a dual production process.
• Design and make fixtures in Pro-E using DFMA guidelines to be able to transport on the shop floor and to vendors engines and transmissions of different truck brands reducing safety issues and increasing mobility among work centers by 15 %.
• Quoted lathe machines in Taiwan costing a third of the price than the domestic competition.
• Team up with Quality to set up Standards for ISO 9001-2008 approval.
• Recommended purchase of air compressors, air dryers, washer pressure equipment, water treatment equipment and lubrication equipment to be use in the testing and shop floor area, wash bay area, and lube area respectively.
• Designed and built buildings to protect exposed production equipment against bad weather, also preventing to have down time in the process.
• Worked closely with EHS Manager to overcome issues related to safety and environmental, all risky issues were resolved.
TEXTRON MARINE AND LAND SYSTEMS, New Orleans, LA 2010 – 2012
Manufacturing / Tooling Engineer.
Designed fixtures, jigs, shop floor aids and any tooling for all Armor Security Vehicles from concept to implementation to speed up productivity and increase efficiency in the production floor. Reduced by 15% extra labor cost distributed among operational steps or routings that did not add value to the products. Conducted feasibility studies to change welding manufacturing processes to robotics to increase productivity. Reverse engineer tools using Solid Works to develop, maintain and outsource major welding fixtures for labor cost reduction. Provided guidance to other manufacturing engineers.
• Designed and created a fixture to weld the Front Differential Assembly of the TAPV Canadian armor security vehicle, increasing productivity by 15 %.
• Redesigned for continuous improvement the main tack welding fixture for welding and building the TAPV model, resulting in a reduction of 10% labor hours, at the same time improving accuracy of the location of welded assemblies.
• Used FMEA to perform root cause analysis to investigate assembly issues.
• Developed a tool to weld appliqués and studs on ASV armor security vehicles, increasing the welder’s efficiency by 10%.
• Designed from concept to implementation a universal front and rear axle mounting fixture for all different armor security vehicles, increasing productivity in that area by 20%.
• Redesigned for continuous improvement Alignment Plates shop floor aids to make them adjustable, safer to fit all armor vehicle variants, in addition minimizing the process time in that area by 15%.
• Designed from concept and created ballistic door seam tool fixtures for handling large parts in the blast and paint area, increasing operator’s efficiency by 20%, in addition improving ergonomics for the whole paint team.
• Designed a turret flip over fixture to be use with a mechanized system to be able to outfit turrets with accessories in a safer way, in addition improving ergonomics and operator’s efficiency by 25%.
• Reverse engineer 40mm, and 50 caliber aluminum calibration guns to be use as mock ups needed to improve, adjust and synchronize accurate aiming of the turrets guns.
• Used SPC metrics for measuring production parts to control major variables in the process that can impact the final product.
• Reverse engineer for improvement and accuracy the engine and t-case mount location fixture in all ANA, ASV, TAPV variants models, increasing productivity in this station by 20%.
• Reverse engineer for improvements in Solid Works the rotary hull rollover fixture to weld out all vehicles reducing the amount of steps by 15%.
OSHKOSH TRUCK CORPORATION, Start up Facility, Killeen, TX 2008 – 2010
Senior Process Engineer
Designed and created work instructions, assembly process sequence, production parts routings and BOM for the weld shop, paint shop, and assembly line areas. Conducted time and motion studies and line balancing of the process based on variable takt time. Used Lean Manufacturing Techniques for waste reduction and increased plant’s throughput. Supervised the maintenance supervisor and maintenance helpers.
• Created a flawless production process generating an Army truck cabin every 2.25 Hrs by simplifying work instructions, and using visual aid and easy schematics to read in the whole process.
• Designed in AutoCAD the initial facility process layout to produce Army truck cabins based on knowledge of the metal fabrication process, ability to visualize spatial and time requirements, and knowledge of the product.
• Significantly decreased the amount of production labor costs from 130 to 55 hours per cab, by solving all bottle necks in every work center, also diminishing to zero the waste time of waiting for parts or machines, and reducing the cycle time in most operations.
• Increased the operator’s efficiency from 70%-98% by identifying room for improvement, evaluating the current process, and design...
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