Alek Zemczykowski

Alek Zemczykowski


Highly accomplished engineer in manufacturing/production environments. Track record of success in designing processes and equipment that increase productivity and reduce costs. Highly organized, efficiently coordinating activities and building productive cross-functional teams. Proven ability at implementing Kaizen principles in lean manufacturing environment. Experience with QS 9000 standards and automotive mass production. Master of Science degree in Mechanical Engineering. Adept at utilizing AutoCAD 2D and 3D, MicroStation 95, Word, Excel, Project, Outlook and SAP 5.0, plus Allen Bradley, V+, and AIM Motion Ware programming. Capable of developing unconventional methods for effectively resolving problems.


  • Project Management
  • Lean Manufacturing
  • Production Analysis
  • QS 9000
  • Equipment Design
  • Kaizen Principles
  • Problem Solving
  • TeamBuilding
  • Personnel Management
  • Technical Presentations
  • Fluent in English, Polish, German and Russian

Work History

Work History
Nov 2010 - Present

Manufacturing Engineer III

Gardner Denver , Thomas Division

Directed several assembly lines producing Dry Running WOB-L Piston Pumps, Diaphragm Pumps and

Articulated Piston Pumps .

Expertly design and install manufacturing equipment.  Evaluate existing production processes in order to implement new equipment and advanced manufacturing methods to increase quality and production output.  Produce documentation including standard operating procedures and technical manuals.

Key Achievements:

  • Successfully implemented the production process of a new model of the Diaphragm Vacuum        Pump.
  • Provide technical support and expertise to 28 production cells.
Jan 2005 - May 2009

Senior Manufacturing Engineer

Linde Material Handling

Served in engineering support role for final assembly of Electric Lift Truck.

Developed, evaluated, and improved production processes for final assembly line. Provided workforce training of manufacturing line employees. Supplied daily technical support to production line.

Key Achievements:

  • Planned, directed and coordinated the line design, layout and implementation, design of assembly equipment and fixtures, selection of all tools including torque control tools, and creations of manufacturing instructions for 3,500-pound E18 and 4,000-pound E20 electric lift truck worth $3.7M.
  • Directed the transfer of the production line (worth $1.5M) and daily support for the 3,000-pound ER18 electric lift truck from Germany to Summerville, SC.
  • Provided daily support to five lift truck production lines.
May 2000 - May 2004

Manufacturing Engineer

Electrolux Home Products

Served in engineering support role for final assembly of Garden Tractors.

Designed and modified production process for final assembly line producing 1,400 tractors per day. Developed tooling and fixtures. Implemented Kaizen principles in lean manufacturing environment. Served as departmental liaison on companywide improvement team, continually contributing effective ideas.

Directed installation of fixtures and new equipment. Oversaw workforce training. Provided daily support to production line.

Key Achievements:

  • Implemented numerous design and process improvements, increasing overall line production by 65% and per-person productivity by 100% while reducing operating costs by 35% by December 2003.
  • Coordinated implementation of the "New Tractor" into production.
  • Designed and implemented new supply-chain process utilizing conveyors and power lift/tilt tables, allowing materials to be delivered at beginning of conveyor rather than to individual workers. This enabled team members to use materials on as-needed basis rather than depending on delivery from warehouse.
1998 - 1999

Process Engineer

General Cable

Recruited due to outstanding analytical and problem-solving skills to solve numerous production problems for plant manufacturing cable and copper rods.

Analyzed problems in manufacturing process and developed solutions. Coordinated technical support for 19-wire copper circuit production equipment. Wrote technical manuals, standard operating procedures, and work instructions. Coordinated activities with equipment and tool vendors.

Key Achievement:

  • Analyzed production process and implemented program that reduced machine speed, leading to significantly fewer machine breakdowns and damaged cables, increasing productivity by 60%.
1993 - 1998

Manufacturing Engineer

Sanden International USA

Directed assembly line producing scroll-type automotive air-conditioning compressors.

Expertly designed and installed manufacturing equipment. Directed installation and testing of plant’s first fully automated robotics station. Developed and implemented training program for employees. Analyzed production processes and developed improved equipment and methods that reduced waste and product

rejects. Created technical manuals and standard operating procedures.

Key Achievements:

  • Successfully redesigned 21 test benches within one year, increasing test capability by 100%.
  • Prepared complete documentation that enabled assembly line to meet QS 9000 standards.
  • Effectively designed and installed manufacturing equipment that increased productivity by 20% while improving quality, reducing ppm rejects to less than 50.


1970 - 1976


Silesian Technical University

Since its opening in 1945, the Faculty has graduated 7837 MSc engineers, 8618 BSc engineers, conferred 532 PhD and 87 DSc degrees in technical sciences.



AutoCAD, 3D Modeling, and Technical Presentations

Collin County Community College – McKinney, TX

V+ Programming and Robot Maintenance

Staubli Automation– Duncan, SC

Allen Bradley Programming

Rockwell Automation Training Center – Dallas, TX

V+ Advanced Programming and AIM Motion Ware Programming

Adept Technologies – San Jose, CA