Dennis Berkemeier

Dennis Berkemeier

Objective

Introduction:

I have Project Management experience in concurrent engineering and management of cross functional teams (including suppliers) created to develop new processes which through rigorous testing and measurement are known to meet all customer expectations and requirements including visual and surface finish requirements. These requirements were audited by the customers Quality Engineers and have met their requirements. Through concurrent engineering product development cycle times have been reduced. I have managed many new manufacturing processes and new model changes from concept to delivery including packaging.

Through structured program management requirements, period audits and checklists new processes are accomplished in remarkably short time lines and right the first time. Projects have design reviews including reviewing of lessons learned from the previous projects. The need for poka-yokes are reviewed and included in the initial designs. Through creation of Control Plans, Design Failure Mode and Effect Analysis (DFMEA's), Process (pFMEA)', Machine (mFMEA's) and Logistic (lFMEA) it is possible to plan for potential failures and opportunities for failures and reduce much waste in the process . All designs, processes and cycle times, fixtures, gages, and etc were validated to meet all intended requirements. Customer key characteristics are evaluated and included in the Control Plans, Work Instructions, and process data sheets including quality requirements.

All processes have signed process control documents, work instructions, training matrix, TPM documents and safety checklists available at each process. Each process in validated for cycle time, ergonomics, safety, reproducibility, and repeatability. All calibrated equipment are evaluated for drift over time (TBC) Time between Calibrations, and (MTBF) Mean Time between failures. All poka-yoke sensors are validated and maintenance personnel are included in the training matrix.

All new processes are validated against the original cost estimates and periodically reviewed. Since customers are expecting to see process improvements in new processes leading to a price reductions these considerations are reviewed in new contracts in detail. These expectations include new process ideas to improve chronic process problems leading to customers complaints. This then leads to a reduction in scrap and rework costs. This is the impact point of incorporating completed six sigma programs that can affect manufacturing costs and improve ability to obtain new contracts

Personnel from the( APU) business units were included in the cross functional teams. Operators were used for the run off of new equipment and fixtures and there suggestions were incorporated into the equipment and fixtures before shipment of the equipment. Safety engineers completed safety check lists before shipping.

ISO 9000 (Quality Management Systems) and TS 16949 ( Environmental)audits were conducted periodically to ensure compliance to customer and regulatory agencies requirements. Also supplier quality audits were conducted and PPAP requirements were followed closely for new products and processes.

Thank you for reading this cover letter and I am looking forward to discussing this position with you in detail.

I have experience in manufacturing plant design and expansions including contracting Architects, plating and boiler installations, heavy duty machines with foundations and use of rigger companies for movement by low-boy trucks or by rail. I have supervised Engineers, Tool makers, fabricators, machinists, and inspectors.

Education:

Bachelor of Science in the area of Mechanical Engineering and Technology – Purdue University

Associate in Applied Science in the area of Industrial Engineering – Purdue University

Certifications and certificates:

Certified Quality Engineer (ASQC) 18528, Lead Auditor Training ISO 9001:2000 TS 16949 AQS Q9381

Time Study, Fracture and Failure Analysis, Circle Grid Analysis, Powder and Lubricants in the PM Industry, Metallography,

Process Validation/Qualifications: (Validating product or process operates the way it was designed to operate)

APQP (Advanced Product Quality Planning)

PPAP (Production Part Approval Process)

Design Validation (DV) and Process Evaluation (PV)

Project Management

Microsoft Project

(PSO) APU, Quality and Customer Audits

Experience with Pert Charts

Knowledge of Critical Chain Methodology

Knowledge of Earned Value Management Systems (EVMS)

Schedule Risk Analysis (SRA) experience

Six Sigma basic training

Current Status:

Unemployed (November 19, 2008) job eliminated due to economic conditions

Relocatable anywhere, travel up to 75%, United States citizen, no record, no security clearance

Standards:

ISO 9000, TS16949, ISO 13485, ISO 14001,GMP, ISO ICS 25, ISO ICS 21, ISO ICS 27, MIL-STD 108E, Knowledge of MIL-DTL-81927, MIL-DTL-81928, MIL-DTL-81929, and S1000D.

Experience in Industries:

Supplied product to automotive, casket, heavy duty truck, aircraft, medical, wire and cable,

telephone, elevator /escalator, textile, plastic, rubber, lumber, food, agricultural, construction

Experience in processes:

Patent development and implementation, Injection molding, stamping blanking, forming, drawing, investment castings, steel castings,

powdered metal, welding, brazing, soldiering, die casting, grinding, milling, drilling, broaching, lathing, rubber extrusions, automated assembly lines, packaging design and specifications, vision measuring systems & Cognex systems, powder coating, plating, vibratory finishing, chamfering, tensile testing, substrate preparation (washing and cleaning systems) sheet metal fabrication, coining, embossing

profile machining, polishing, burnishing, honing, sewing, embroidery, automated cutting of cloth

Machines:

Mills Cincinnati, Lagun, Brown and Sharp, Cincinnati grinders OD and ID, Sunnet Hones (bearing raceways)

Mazak, Okuma, Mori Seiki, Hardinge, lathes, Hobart welding mig (GMAW) and tig (GTAW), Bliss, Federal, Empro, Version, Niagra presses, Wabash liquid injection molding (medical) Milacron injection molding machine Meiki rubber injection molding (gaskets), Sailor robots for molding machines (pick and place) and conveyors ,Allen Bradley and Fanuc Controls, Variable Frequency drives

Abbott continuous furnaces, Cincinnati CNC press brakes, CNC punch, CNC folding machines.

Products:

Gears, sprockets, pistons, main bearings, ball bearings, thrust washers, caskets, pneumatic tools rings, elevators, faucet components, hospital beds, monitors, pillow block bearings, value guides, valve seats, stampings, plastic components, glass bottles, plastic bottles, castings iron and steel, investment castings,

Experience in materials:

Steels (1020, CRS, 52100, 4140, 8620, 302 stainless,) Aluminum (6061 T6) Cast Iron,

Plastics (polycarbonate, nylon) M series mold, also S1,D2, A2, tool steels

Other related skills and training:

Word, Excel, Access, MRP, SAP, Visio, Powerpoint, Vista, AutoCad, Pro-E, Master Cam, MS Project, PDF, Lotus notes and databases.

RS logic and panelbuilder., Knowledge of SLIC

Knowledge and experience with Logistics Management Information software such as EAGLE or SLIC.

A working knowledge of MIL-DTL-81927, MIL-DTL-81928, MIL-DTL-81929, and S1000D.

Writing experience including inputs to technical proposals and Integrated Logistics Support (ILS) plans.

·         Knowledge and experience with publishing software such as Arbortext and SGML tagging.

·         General knowledge of Condition Based Maintenance and Performance Based Logistics.

Education

Education

Bachelor

Education:

Bachelor of Science in the area of Mechanical Engineering and Technology

Associate in Applied Science in the area of Industrial Engineering

Work History

Work History

Process Engineer (New Model) VPS Supervisor

Valeo Engine Cooling

Valeo is a designer and manufacturer of heating and cooling modules (heat exchangers- radiators, condensers and transmission oil coolers) for the domestic and foreign automotive industry. 

Responsibilities

Project Management

-Assigned and managed projects from Strategic Business Plan from concept to delivery

-Co-ordinate with product development. Create product and process specifications.

-Design for manufacturability (DFM)

-Project tracking – MS project

-Resource allocation – Autonomous Production Unit (APU), maintenance, facilities, quality, engineering

-Cross functional team creation for product and process development

-APQP, PPAP requirements established

-Design Reviews, Lessons learned cards reviewed and updated as required, Poka-Yokes, review (CAPAs)

-prototype fabrication programs-Management reviews of project status. Strategic Activity Reviews (STAR), schedules, deliverables,

-Logisitcs

-Service centers

-Packaging, skids, special designed racks

-Plant design and expansions - contracts using Architects, 

-Equipment installation with foundations and use of riggers and outside contractors

Process/ Manufacturing Engineering and Control

-Participate in cross functional teams associated with cost reductions and process improvement ideas. Continuous Improvement (CI), Value Improvement Process (VIP),

-Executing, developing, and administering, procedures and protocols

-Write work instructions, procedures, and process control documentation. Standardization of operating conditions,

-Designed and maintained machines, tooling, gaging, material handling and packaging.

-Value Stream Analysis (VSA), Process Flow Diagrams (PFD)

-Apply Lean Manufacturing Principles as required

-Kaizen, SMED, JIT, VPS(TPS), Kanban, Time Study, line balancing,Standard Work

-Poka-Yoke and Autonomation for machines and tooling as required

-Design of special equipment and processes as required for process improvements

-Machine and Tooling run off at Vendor and Valeo Capability Studies - Qualifications

-ASTM, UL, ISO 9000, TS 16949, Federal Register, and OSHA standard compliance

-Design, Process, Logistics, and Machine FMEA

-Engineering change requests (ECR)

-AutoCad, FEA,

-APQP, PPAP, PSO, Gage R & R, Capability Studies, Process Data Sheets, First Piece Articles, Calibration,

-Resource training and certification

Quality Principles and Problem Solving

-Quick Response Quality Control (QRQC)

-Quality cost reporting – warranty, in process scrap- PPM

-Machine and Process capability studies

-Corrective and Preventative Action (CAPA)

- 5-Whys 2h's, 8D, Pareto, Fish Bone, Factor Tree Analysis, opportunities for failure, root cause analysis, regression analysis, affinity diagrams, brainstorming, cause and effect, frequency diagrams, response surface methodology, scatter plots.

-Statistical Process Control (SPC), Plan DO Check Act (PDCA), Define, Measure, Analyze, Improve, Control (DMAIC)(6-Sigma)

-Participate in supplier audits

-Participate in-process ISO and TS Audits , now including decomposition of products

-Bar code and product marking for traceability

-Validations - capability studies

Processes

-Automation, rolling, forming, punching, brazing, assembly, torque control (Atlas Copco)

-Validation of PLC controllers, poka-yokes, sensors

Product Testing

-Thermo-cycle, vibration, leak testing, corrosion, chemical analysis (SEM), Tensile testing, failure and fracture analysis, microscopy

Accomplishments:

-1.3 million dollars in new business Mazda J61J New equipment, fixtures, gages, work instructions , poka-Yokes, etc

-1.2 million dollars of new business from BMW new induction brazing project

-1.5 million dollar of new business from Chrysler -New design eliminating exterior transmission oil cooler by incorporating into the tubes in the condenser.

-Value stream savings cycle time reduction $30,000

-Design of special returnable tubular frame racks for shipping of heating and cooling modules $ 80,000 / year

Reason for leaving:  Job elimination

Dec 2004 - Nov 2007

Quality Engineer (QIT)

Sintering Technologies Inc. (STI)

 Sintering Technologies Inc. is a Japanese owned company and division of Hitachi which manufactures value guides value seats, sprockets and gears made out of powder metal. Process recycles off fall from stampings and reprocesses it into iron powder which is used in the powdered metal process. 

Responsibilities: Quality Improvement Team Supervisor -Supervised three in-process inspectors (Three shifts)

-Team leader for cost reduction program for discard loss, -Prepared sintered lab samples for laboratory testing -Stress testing until failure and microstructures -Purchased and programmed Crysta C776 Mitutoyo CMM CNC machine for new Honda Business

-Measured sprockets and gears. Lead and face error, teeth profile, and overall dimensions

-Programmed manual Mitutoyo CMM for repeating final inspection of sprockets and gears-Responsible for customer quality accounts. 8D reports, containment, DMAIC (6-Sigma)-Organized outside sorting of product, (Product Action Company) -Entered warranty claims in SAP -Team leader for quality incentive program. -Installed and monitored SPC on critical operations -Used micrometers, calipers, surface finish, -Also profile measuring equipment, bore gages, -Advanced Product Quality Planning (APQP) team member.

-PPAP-Completed first piece dimensional layouts for all new product -Completed 30 piece capability studies for all new product-Member Material Review Board -Supplier audits and yearly process audits -Special process improvement projects (Powder segregation)-Troubleshoot PLC, electrical, pneumatic, and hydraulic controls

-Packaging requirements and specifications.

-Plant design and expansions - contracts using Architects, 

-Equipment installation with foundations and use of riggers and outside contractors

Accomplishments:

-Special process improvement project- Reduce powder segregation by 10% (New funnel equipment on mixers) $100,000

-Purchased new Mitutoyo Crysta 776 CMM as requirement for new Honda business $1.3 million in sales

-Designed New process to prevent powder segregation $100,000 and powder loss.

-Design of special carton and pallet for shipment VTC sprockets to Mexico. $30,000 in corrosion prevention

-Created cost reduction program. 

Reason for leaving:  Better Job offer from Valeo Engine Cooling

Jan 2003 - Dec 2004

Project and Process Engineer

Mathews International

Responsibilities

Project Management

-Projects from Strategic Business Plan from concept to delivery

-Co-ordinate with product development. Create product and process specifications.

-Design for manufacturability (DFM)

-Project tracking – MS project

-Resource allocation – Autonomous Production Unit (APU), maintenance, facilities, quality, engineering

-Cross functional team creation for product and process development

-APQP, PPAP requirements established

-Design Reviews, Lessons learned cards reviewed and updated as required, Poka-Yokes, review (CAPAs)

-prototype fabrication programs-Management reviews of project status. Strategic Activity Reviews (STAR), schedules, deliverables,

-Logisitcs

-Service centers

-Packaging, skids, special designed racks

-Plant design and expansions - contracts using Architects, 

-Equipment installation with foundations and use of riggers and outside contractors

Process/ Manufacturing Engineering and Control

-Seams in lids mig (GMAW) welded (fixtures)and sanded (fixtures). TIG (GTAW) weld 

-Seams mig (GMAW) welded on special body weld fixtures

-Special continuous parts cleaning line – monitor chemicals, PH, temperatures and concentrations

-Paint and clean room – paint guns, nozzles, measure viscosities, sample panels for testing

-Special interior sewing machines and embroidery machines

-Continuous interior assembly lines.

-Automated packaging line and dock warehousing.

-Created team for Production Preparation Process (3P) -3P for creation of special machines and processes

-Fixture design for welding of caskets, robotics, Tig (GTAW) and Mig (GMAW)welding

-Created Training matrix for welders and maintained by personnel (union shop)

-Team Created Design FMEA, the Process FMEA, Machine FMEA -Created Flow Process analysis (PFD) Value Stream Analysis (VSA) -Created Process Data Sheets, process steps, prints with datums -Created and critical characteristics, cycle times, poke yokes -Conducted design reviews, reviewed lessons learned cards -Obtained equipment quotes -Entered in MRP Requests for quotations, purchase requisitions, -Wrote Work instructions, procedures, safety check lists -Installation of Lean Manufacturing -Cellular concepts and Just In Time (JIT) Kanban, -Maintained Routings, Bills of material, MRP, -Modified and created AutoCad drawings as required -Conducted Single minute change of dies (SMED) workshops -Projects with continuous improvement department -Team leader for Kaizen, standard work, line balancing, time studies, -Conducted equipment, process, gaging (R&R), -Team leader for cost reduction programs -Scrap Reduction, Floor space required, labor, safety -Troubleshoot PLC, electrical, pneumatic, and hydraulic controls

-Requisition required personnel and train operators to Work Instructions

-Container shipment packaging requirements

Quality Principles and Problem Solving

-Problem Solving. 8D, 5-whys, PDCA, Pareto, factor analysis, Root cause analysis,DMAIC (6-Sigma)

- (ASTM D-7378), (ASTM D-3363), (ASTM D3359),(ASTM B117), (ASTM D1014), (ASTM D2794)

-Eddy Current weld testing for in-process testing of welds

-Periodic metallurgical testing and examination of weld samples

-Team leader for trial runs APU, Quality, and Customer (PSO)

-First piece layout, capability studies , -Validations

-Conducted packaging studies with customer support -Product testing life cycle, calibrations, vibration,

-Participated in supplier audits and yearly process audits

-Completed first piece dimensional layouts for all new product -Completed 30 piece capability studies for all new product-Member Material Review Board

-Bar code and product marking for traceability

-Validations - capability studies

Accomplishments:

-Die improvements $132,000 in savings – reduced scrap

-Design of special trailer supports and frame for double stacking of caskets- $100,000 in reduced shipping costs

Reason for leaving: No financial support for projects

Feb 2000 - Dec 2002

Project / Process Engineer

 Nation's largest casket company, Hospital beds and supplies, patient support systems, non-invasive therapeutic products for a variety of acute and chronic medical conditions, medical equipment rentals, and information technology solutions since 1929. 

Responsibilities

Project Management

-Projects from Strategic Business Plan from concept to delivery

-Co-ordinate with product development. Create product and process specifications.

-Design for manufacturability (DFM)

-Project tracking – MS project

-Resource allocation – Autonomous Production Unit (APU), maintenance, facilities, quality, engineering

-Cross functional team creation for product and process development

-APQP, PPAP requirements established

-Design Reviews, Lessons learned cards reviewed and updated as required, Poka-Yokes, review (CAPAs)

-prototype fabrication programs-Management reviews of project status. Strategic Activity Reviews (STAR), schedules, deliverables,

-Logisitcs

-Service centers

-Packaging, skids, special designed racks

-Plant design and expansions - contracts using Architects, 

-Equipment installation with foundations and use of riggers and outside contractors

Process/ Manufacturing Engineering and Control

-Seams in lids mig (GMAW) welded (fixtures)and sanded (fixtures). TIG (GTAW) weld bronze caskets

-Seams mig (GMAW) welded on special body weld fixtures

-Special continuous parts cleaning line – monitor chemicals, PH, temperatures and concentrations

-Paint and clean room – paint guns, nozzles, measure viscosities, sample panels for testing

-Special interior sewing machines and embroidery machines

-Continuous interior assembly lines.

-Automated packaging line and dock warehousing.

-Created team for Production Preparation Process (3P) -3P for creation of special machines and processes

-Fixture design for welding of caskets, robotics, Tig (GTAW) and Mig (GMAW)welding

-Created Training matrix for welders and maintained by personnel (union shop)

-Team Created Design FMEA, the Process FMEA, Machine FMEA -Created Flow Process analysis (PFD) Value Stream Analysis (VSA) -Created Process Data Sheets, process steps, prints with datums -Created and critical characteristics, cycle times, poke yokes -Conducted design reviews, reviewed lessons learned cards -Obtained equipment quotes -Entered in MRP Requests for quotations, purchase requisitions, -Wrote Work instructions, procedures, safety check lists -Installation of Lean Manufacturing -Cellular concepts and Just In Time (JIT) Kanban, -Maintained Routings, Bills of material, MRP, -Modified and created AutoCad drawings as required -Conducted Single minute change of dies (SMED) workshops -Projects with continuous improvement department -Team leader for Kaizen, standard work, line balancing, time studies, -Conducted equipment, process, gaging (R&R), -Team leader for cost reduction programs -Scrap Reduction, Floor space required, labor, safety -Troubleshoot PLC, electrical, pneumatic, and hydraulic controls

-Requisition required personnel and train operators to Work Instructions

-Container shipment packaging requirements

Quality Principles and Problem Solving

-Problem Solving. 8D, 5-whys, PDCA, Pareto, factor analysis, Root cause analysis, DMAIC (6-Sigma)

- (ASTM D-7378), (ASTM D-3363), (ASTM D3359),(ASTM B117), (ASTM D1014), (ASTM D2794)

-Eddy Current weld testing for in-process testing of welds

-Periodic metallurgical testing and examination of weld samples

-Team leader for trial runs APU, Quality, and Customer (PSO)

-First piece layout, capability studies ,Conducted packaging studies with customer support -Product testing life cycle, calibrations, vibration,

-Participated in supplier audits and yearly process audits

-Completed first piece dimensional layouts for all new product -Completed 30 piece capability studies for all new product-Member Material Review Board

-Bar code and product marking for traceability

-Validations - capability studies

Accomplishments:

-Installation of new cell in Manchester Tennessee plant. Injection molding, sputter coat, top coat and UV Cure. $325,000

-Lid forming cost reductions $150,000

-Installed lid brushing capacity in Manchester plant enabled $1.3 million in additional sales

-Application of Lean Manufacturing and Value stream Analysis

Reason for leaving: Job elimination

Mar 1998 - Feb 2000

Manufacturing / Industrial Engineer

 Division of United Technologies Inc. Worlds largest manufacture of elevators, escalators, and moving walkways. 

Responsibilities: (Engineer for the car frame Focus Factory)

Project Management

-Projects from Strategic Business Plan from concept to delivery

-New capital purchase of new cnc saw

-Revise automated cnc press brake material handling system.

Process/ Manufacturing Engineering and Control

-Welding of car steel frames, stainless steel elevator doors, Aluminum brackets and components.

-Use Weld Office Suite for managing welding documentation. Welding procedure software (c-Spec)

-Supervised and responsible for training matrix of certified welders in GTAW, GMAW, FCAW, SAW, SMAW -Team created Design FMEA, the Process FMEA, Machine FMEA -Created Flow Process analysis (PFD) Value Stream Analysis (VSA) -Created Process Data Sheets, process steps, prints with datums -Process Data sheets also contained critical characteristics -Also cycle times, poke yokes -Wrote Work instructions, procedures, safety check lists

-Requisition required personnel and train operators to Work Instructions-Installation of Lean Manufacturing -Also cellular concepts and Just In Time (JIT)and Kanban systems -Maintained Routings, Bills of material, MRP, -Modified and created AutoCad drawings as required -Conducted Single minute change of dies (SMED) workshops -Team leader for trial runs APU, Quality, and Customer (PSO)

-Projects with continuous improvement department -Team leader for Kaizen, standard work, line balancing, time studies, -Conducted packaging studies with customer support -Team leader for cost reduction programs -Programs for scrap reduction, floor space required, labor. -Troubleshoot PLC, electrical, pneumatic, and hydraulic controls

-Responsible for packing and shipping specifications.

Quality Principles and Problem Solving

-Product testing life cycle, calibrations, vibration,

-Conducted equipment, process, gaging (R&R) -Also capability studies, Validations

-Participated in supplier audits and yearly process audits

-Problem Solving. 8D, 5-whys, PDCA, Pareto, factor analysis, Root cause analysis,DMAIC (6-Sigma)

Accomplishments:

-Reduction of Work In Process (WIP)

-Made 10,000 square feet of work space available

-Reduce cycle time by three days – Value Stream Analysis

-New CNC saw savings of $140,000 / year

Skills

Skills

MasterCam

Used for CadCam CNC lathes and mills

Adobe Photoshop

Photographs for work instructions and presentations

Acrobat

Create and edit PDF files

AutoCad

Design and modification of tools and fixtures.  Design of special machines.  Plant layout Finite Element Analysis. Mass, 

PowerPoint

Presentations

General Office Equipment

Fax machines, copiers, printers, plotters, shredders, personal computers, scanners, laminators,

Microsoft Excell

Used in Work Instructions, tables, reports, 

Microsoft Word

Used in technical reports, memos, letters, envelops, tabs, agendas, Work Instructions, Procedures, Process Control Documents,

Certifications

Certifications

Lead Auditor Q9381

AQS

Quality Engineering

ASQC 18528