- Road Cycling
- Member - North Georgia Cycling Association, CycleWorks club
- Presentation to the Ingersoll-Rand Technology Council on discrete-event system simulation, “Application of Computer Simulation in Design of Automated Assembly Lines”
- Presentation to the company-wide Industrial/Manufacturing Engineering Forum, “Modeling of Manufacturing Systems”
- Presentations for internal technology transfer seminars: “Lean Manufacturing”, “Manufacturing Systems Simulation”
- Technical papers: “Economic Justification of Shop Floor IT”, “Identifying Risk and Uncertainty in Manufacturing Process Design and Cost Estimating for New Products”
A Project Engineer position, requiring analytical skills and experience in Industrial or Manufacturing Technology Engineering.
- Knowledge of Geometric Dimensioning and Tolerancing ASME Y14.5 Standard
- Member – American Institute of Industrial Engineers
- Instructor - Lean Manufacturing, Pull System Concepts, Process Failure Mode and Effect Analysis (PFMEA), 6-Sigma
- Language Skills – German, basic familiarity with technical language; Russian, fluent
Engineering professional with strong technical and business abilities gained from 15 years experience working as an R&D Manufacturing Project Engineer in world-class, Fortune 500 organizations. Demonstrated accomplishments in engineering analysis, research, project management, process/product implementation, quality management, supervision, budget planning, and cost analysis. Strong project leader, negotiator and communicator; significant analytical and computer skills. Outstanding problem solving capabilities. Proven management abilities working with diverse cultures at all levels of the organization.
Expertise in Lean Manufacturing, Toyota Production System, Value Stream Mapping, 5S, Kaizen facilitation and Six Sigma methodologies. Experienced with manufacturing process controls methods: FMEA, PPAP, APQP. Hands-on experience in conducting Design of Experiments (DOE), SPC and advanced statistical analysis. Lean Six Sigma certified.
2006 - 2008
Senior Quality Engineer
Schick Wilkinson Sword - Global Research, Development and Engineering Center
Responsible for providing quality management and direction to product development teams to achieve best in class quality standard requirements in all phases of new product and process development.
- Evaluated new products, manufacturing processes and measuring equipment against Schick global quality standards.
- Developed tests, sampling plans, statistical methods and data analyses for blade process validation protocols.
- Worked cross-functionally with research, new product development teams, manufacturing facilities in Germany and China to provide quality support during the new product development phases.
- Reduced product test cycle 30% by implementing laser gage for measurement of blade angles and cartridge geometry.
- Applied design for 6-Sigma (DFSS) and advanced quality planning tools to produce robust design of new products.
- Managed documentation related to quality standards, work instructions, methods for inspection and training.
- Conducted internal audits of quality management systems for ISO9001/2000 compliance.
2003 - 2006
Program Manager/Principal Industrial Engineer
Timken US Corporation - Manufacturing Research and Development Center
Responsible for development of new manufacturing systems and advanced processes for Timken Automotive Division.
- Conducted process development, budget planning, cost justification, and system simulation analysis for Variable Valve Actuator designed for Daimler Chrysler HEMI and Viper engines.Performed VA/VE analysis of product and process.
- Led industrial engineering team effort in grinding process rationalization utilizing Value Stream Mapping (VSM) in economic justification of $2M multi-surface CNC grinding equipment for Solid Race Bearing plant in the Czech Republic.
- Achieved $380K in manufacturing savings by developing and implementing an automated single minute die-set exchange (SMED) and maintenance line for Needle Bearing Drawn Cup presses at the Sylvania, GA facility.
2000 - 2003
Lead Industrial Engineer
Responsible for development of innovative manufacturing systems for bearings and precision automotive components.
- Performed computer simulation analysis, process planning and geometric dimensioning & tolerancing variance analysis for high volume GM Delphi Valve Tappet manufacturing lines in France and Cairo, GA
- Led lean manufacturing effort in process development for A-class Mercedes-Benz steering column in Russia.
- Conducted process development, economic cost analysis and design of experiments (DOE) for innovative models of Laminated Planetary Gear Carrier for automatic transmissions.
- Developed new facility layout and production lines by utilizing value stream mapping of processes and adopting the latest lean manufacturing concepts for Solid Race Needle Bearing facility in the Czech Republic.
- Managed implementation of Lean Manufacturing and Toyota Production System principles through Dodge Intermediate Steering Column assembly lines in Watertown, CT plant.
- Justified $6M investment into new German heat treatment technology.Managed $2M annual savings proposal to centralize heat treatment operations for through-harden radial ball bearing components.
1998 - 2000
Senior Project Engineer
Responsible for material handling support in implementation of the new, technologically advanced, high-speed presses to produce thrust bearings for automotive transmissions and power-train applications.
- Developed an automated press material handling system and implemented working model of press work-center based on a new technology high-speed Minster press.Proliferated installation of proven modular material handling systems throughout the entire thrust bearing stamping department at Needle Bearings Plant in Clinton, SC.
- Demonstrated automated material handling support at high-speed press operations with 50% reduction in man-machine interference and 13% reduction in press downtime.
- Proposed pilot shop-floor IT solution to automate all process control functions performed by press operators at press work-centers.Implemented KANBAN-based system for raw material ordering and delivery.
1993 - 1998
Industrial Project Engineer
Responsible for industrial engineering projects and support of Torrington’s manufacturing facilities.
- Applied Process Failure Mode Effect Analysis (PFMEA) to analyze operations of Machine Tool ABEC-7/9 bearing assembly.Identified failure root causes producing significant damage to bearing raceway surface.Produced $120K in savings by eliminating complaints and returns from major machine tool customers.
- Led series of Kaizen events at the Radial Ball Bearing assembly in Calhoun, GA, resulting in implementation of flexible, compact bearing ball feeders, 65% setup time reduction, improved ergonomics and floor space savings.
- Designed factory layout, tooling systems, material handling, and KANBAN-based workflow for implementation of $20M low-volume Radial Ball Bearing CNC turning facility in Canton, GA.
- Constructed simulation models of automated Ford F-Series Truck Camshaft assembly lines.Addressed a “floating bottleneck” problem and determined the effect of short stoppages on the robot-driven operations connected by power-and-free conveyor line.Provided set of recommendations that increased production throughput by 30%.
Jan 1990 - May 1993
Thesis - "Computer Simulation of Capacitor Production Line," 1992. IBM - East Fishkill, NY