Recruited to improve productivity, quality, equipment up-time and consistency of laser welding, resistance spot welding, arc welding, assembly and testing processes used to manufacture exhaust system components through improved manufacturing practices, tooling, equipment and maintenance procedures. Planned and implemented new/transferred model launches, determining equipment and tooling needs, purchasing, testing, documentation and integrating processes using standardized work, quick changeover and lean manufacturing principles. *Improved Muffler Cell productivity 27% in first 4 months implementing root cause solutions that improved processes and equipment uptime. *Achieved 50% production increase with less than 25% capacity increase through improved tooling, quick changeover methods and equipment utilization to integrate production from closed Granger, IN plant. *Maintained customer deliveries, integrated 4 new parts, transferred 16 production and 20 service parts. *Project Manager over design, build, and integration of new pallet/base plate system reducing laser weld fixture changeover times by 67% (30 min to 10 min).

Performed activities improving productivity in manufacturing with focus on welding processes across entire plant. Lowered costs, improved quality, implemented error proofing, process monitoring, variation reduction, problem detection, maintenance, documentation and training. LSO; QS9001 Internal Auditor; Laser Team Leader; safety, welding and process audits.Monitored and improved processes over three final converter assembly areas using Six Sigma tools. *Improved processes, equipment, predictive and preventative maintenance procedures that reduced downtime, increased jobs per hour and productivity while improving quality in team oriented structure. *Reviewed customer and warranty returns and implemented manufacturing changes preventing reoccurrence.*Achieved Green Belt certification with project that reduced weld scrap 81.5%, saving $183,000/yr, within 6 months by improving process monitoring and maintenance activities. *Reduced converter contamination 15% with welder and washer process improvements that reduced warranty issues.

Plant-wide responsibility for 24 hour R&M support of Infrared/Vibration/Motor analysis, Bearing/Spindle Room, Electronics Lab, Laser Team, Ford Total Productive Maintenance Team, and Oil usage tracking. Supervised 28+ skilled labor employees in team oriented structure. *Developed, implemented, and trained Laser Team conducting predictive and preventative maintenance checks determining laser equipment health. Problems detected and repaired quickly avoiding unnecessary maintenance, reducing labor, rework and scrap costs, while improving productivity and part quality. *Reduced Helium costs $556,000/yr (71% reduction). *Reduced laser serviceman repair costs, $90,000/yr (95% reduction). *Generated $160,000/yr savings in reduced laser optics usage. *Reduced maintenance material costs $1.5 million per year and reduced downtime through internally repaired components in Electronics Lab and Spindle Room areas. Failure analysis and improved tracking of failures resulted in component or machine design changes that improved equipment performance.*Developed and implemented predictive maintenance procedures for Infrared, Vibration and Motor Analysis to detect equipment problems and implement repairs before failure. Reduced costs and downtime.

Responsible for process control over 4 major departments. *Designed, tested, and installed new equipment, minimizing production downtime and improving manufacturing processes, costs, and productivity.*Improved Constraint Operation processing uptime from 60% to 95%. Replaced 4 semi-automatic with 2 automatic laser systems. $2.7 million project that resulted in $1.5 million/yr savings. *Increased department capacity 25%, productivity 15% at minimal costs by adding only 3 machines.

Developed and enhanced technical interface relationships with current and potential customers through technical presentations. Reviewed issues at manufacturing plants and wrote proposals that solved technical problems. *Interfaced with customers developing laser, resistance and arc welding processes. Provided solutions and production applications that met customer quality and structural requirements at competitive costs.

Established welding procedures for manufacturing and repairing aircraft engine components. Analyzed and implemented solutions to welding problems at GE and suppliers. Environmental, Health, and Safety Representative (EH&S). Department Of Defense Secret Clearance.*Recommended and reviewed new welding/inspection processes and evaluated inspection data at vendor for GE90 Engine Test Mount Adapter. Met critical engine test schedule and all service requirements. *Developed and implemented Electron Beam weld repair procedures for critical engine hardware that insured quality and reliability. *Reviewed and qualified welding procedures (GTAW, GMAW, SMAW, PAW, IW, and EB) for manufacturing that insured process stability resulting in quality and reliability in aircraft engine applications.

Developed YAG and CO2 laser welding, cutting, drilling and marking processes for manufacturing aircraft engine components. Trained and scheduled personnel, machines, and hardware which met necessary production and test schedules. LSO and EH&S Rep. for area. Audited manufacturing areas for compliance to quality requirements. *Managed 85 laser processing jobs (annual labor budget over $680,000) that produced special engineering parts for testing which improved engine performance (i.e. reduced process time from 32 hours Electrical Discharge Machining to 3.5 hours laser cycle time for one part).*Developed and managed four major manufacturing pilot lines resulting in improved engine reliability, service time, productivity and costs (i.e. first structural laser weld in a GE jet engine).*Conducted training, machine maintenance, procedure development and equipment setup in Eskisehir, Turkey resulting in reliable, consistent laser processing of parts in 3 weeks instead of estimated 3 months.

Carried out research and development applications determining equipment specifications and controls for insuring weld quality. Department Of Energy Q level Secret Clearance.