VisualCV

➢ Replaced aging powder coat rack burn-off oven under budget and under schedule, improving effectiveness, increasing capacity by 33%, and decreasing cycle time by 38%.
➢ Developed and implemented a “Pit Crew” set up method for powder coat operation that reduced setup time 47% and resulted in a savings of $71K/year.
➢ Justified and installed a bulk powder feeding system, reducing direct labor and improving consistency of virgin/reclaimed powder ratio.
➢ Conducted thermal profiling of infrared curing ovens to optimize powder cure quality.
➢ Created a new, overall facility layout to optimize process flow through the facility by gathering and analyzing data on processes, products and material flow.
➢ Contributed to implementation of Demand Flow Technology/Lean Manufacturing at Honeoye Falls facility; determined labor and machine capacity, floor space required, Kanban sizing, material storage needs and cell layout.
➢ Co-trained employees in Lean Manufacturing, Kaizen and 5S; participated in several events. Published monthly in-house newsletter on Kaizen and lean manufacturing.

➢ As Team Leader (August 1997-August 1999), supervised 5-8 members of engineering department. Set and monitored team objectives, priorities and budgets; conducted interviews and performance appraisals.
➢ Led, or contributed to, numerous cross-functional teams charged with product design improvements and cost reductions. Led team in product cost reduction resulting in immediate 30% cost reduction and 600% sales increase over six years.
➢ Developed and implemented assemble-to-order cells, reducing finished goods inventory 77%-97% and setup time by 80%. Redesigned workstations, analyzed demand and capacity, determined storage requirements and improved methods.
➢ Justified and acquired an order picker truck, reducing time to replenish component storage flow racks from 5 minutes per item to 2 minutes per item.
➢ Created a database for the analysis of historical demand and shipments.
➢ Submitted engineering changes to solve design, quality or manufacturability issues.

➢ Established, staffed and managed a new manufacturing QA/QC organization for Rochester site. Led and coached staff of 8 with an annual budget of $450K.
➢ Drove site effort towards ISO-9000 quality system certification.
➢ Developed closed loop corrective/preventive action system.
➢ Provided quality engineering support for vendors supplying machined components.

➢ Reduced Total Cycle Time from order receipt to shipment utilizing Time Based Management (TBM) techniques learned from The Boston Consulting Group.
➢ Modeled machine load and capacity to forecast five year capital requirements.
➢ Justified, purchased and installed capital equipment including $250K vacuum furnace which provided $100K/year savings and $100K aqueous parts washer which reduced trichlorethylene solvent consumption by more than 20 tons/year.
➢ Created CAD layout of machine shop and analyzed material flow (Master‘s thesis).

➢ Liaised with customers to satisfactorily resolve any product quality issues.
➢ Developed and implemented custom molded EPS packaging saving $100K/year.
➢ Justified and installed PLC controlled, conveyorized packaging line saving $40K/year.
➢ Designed and implemented system to better purge moisture from compressors.
➢ Performed design work and facility layouts using CAD system.

➢ Developed methods and purchased equipment to rivet / leak test a critical assembly.
➢ Specified, installed and relocated roller and overhead monorail conveyors.
➢ Designed and installed continuous pressure leak / burst test system to reduce rework.
➢ Drafted layout and relocated final electrical test area to enhance material flow.

➢ Developed $1MM automated cell to manufacture valve plates from raw stock to finished product. Expected annual savings of $350K and faster time to market.
➢ Designed and programmed equipment for automatic load/unload of forming press using pneumatics and PLC, saving queue time and five direct labor personnel.
➢ Automated stockroom and parts delivery using horizontal storage carousels and conveyor transporter system, saving 500 square feet and two indirect personnel.
➢ Performed design and facility layouts using mainframe based IBM CADAM system.