Contract Manufacturing/Industrial Engineering

 Let American Technical Analysis puts their experience to work for you and your company needs.

While involved with industry we have had a wide range of responsibilities and successes including New Products Engineering (Manufacturability) involved in multiple product lines from automotive to electronics and heavy equipment including: 

·        Industrial Engineering at The Louis-Allis Company focused its heavy equipment manufacturing instruction sheets on the mission of insuring the consistent methods used to assemble products for the purposes of providing safe assembly processes, insuring consistent product integrity, with minimized cost to their customers. 

o       Louis Allis has been in business for over 100 years and specialize in electric motor manufacturing, military, navy ships, power plants, and industrial applications world wide.

 

o       Among the motors many were provided to the United States Navy and include:

·        Manufacturing Engineering at Johnson Controls, Inc., streamlined and standardized instruction sheets for Building Automation Systems products.  Activities included:

 

o       Leading project “Snow White”, a 22 person manufacturing engineering department effort, to update more than 6000 manufacturing instruction sheets insuring safe, consistent and current cost effective methods used in the production area. 

 

o       Authoring a company standard for the implementation of Engineering Change Orders

 

o       Authoring a standard for wire termination for all products.  This standard was adopted by the Division and administered by the Quality Control department.

 

o       New Product Introductions Teams, responsible for the manufacturability aspects of development projects:

1.      Development and adherence to financial budgets and schedules

2.      All product components and subassembly system entry

3.      Developing safe assembly methods and authoring respective instruction sheets

4.      Initiation of initial production schedules

5.      Meeting the needs of the new product customers

 

• Develop, build, and start-up a new manufacturing facility in Reynosa, Mexico:
  
   

§         All layouts and equipment procurement for the wire processing production area in the Reynosa plant

§         Closing a sister plant in Carrolton, Texas

§         “Redeveloping” the manufacturing methods of the Carrolton Plant products in conformance to the company assembly standard Bruce wrote to insure safe and consistent assembly instruction sheets

§         Overseeing all manufacturing documentation updates

§         Overseeing the pilot run of each of the transfer products at the home plant in Milwaukee, Wisconsin plant and down into the Reynosa plant

§         Layout and equipment procurement of a distribution warehouse in McAllen, Texas

 

·        Manufacturing Engineering at Gould with the design concept, plant layout, management presentations, and program management through completion of the electronic manufacturing facility in Racine, Wisconsin.

 

·        Cherry Electric Company’s Manufacturing Engineering responsible of safe and consistent assembly instructions for Ford and GM armrest escutcheons assemblies.  Including:

 

o       Machine shop,

• Die shop,
• Hand, and automated operations.

·        Contract Engineering methods and instructions development for various company operations including:

• A general welding business in Milwaukee, Wisconsin
• Contract plant layout work, through the completion of assembly, paint, packaging, and shipping facilities for a pad mounted transformer facility in Waukesha, Wisconsin.
• Vibratory finishing products in Germantown, Wisconsin
• Layout design, equipment configuration, construction finalization and start-up of an electric motor manufacturing operation in Elkhorn, Wisconsin.

·        Manufacturing Engineering Department Supervision in addition to:

 

• Performing plant layout,
• Building reconfiguration and
• Production support of an insulator molding, assembly, packing, storage, and shipping facility in Pewaukee, Wisconsin
• Production support of an insulator molding, assembly, packing, storage, and shipping facility in Taipei, Taiwan. 
• Conception and implementation of the company’s first fully automated machine, a Spark Arrestor Assembly Machine:
  
   

§         Hopper and magazine fed

§         Sized, assembled, stacked, inspected, accepted, rejected, and boxed spark arrestors used in the utility industry.

·        Industrial Engineering Manager at Sterling, Inc., with:

 

• Overall department responsibilities in addition to safe methods in the machine ship, weld shop and assembly production areas.
  
   

·        Manufacturing Engineering at Hubble’s Ohio Brass division left a $353,000 “White Elephant” insulator assembly machine (Producing ZERO product and abandoned), requiring:

 

• Reconfiguration of all tooling,
• Implemented SPC
  
   

Realized $250,000 A WEEK in shipments, in addition to:

 

o       Maintaining overall responsibility for the process development,

o       New product introductions,

o       Plant layout,

o       Equipment installation,

o       Assembly, packaging, and shipping for all insulator products in Aiken, South Carolina.

Plus, the development of automatic insertion machine incorporating SPC to insure the proper quantity/dispersion of the dielectric grease, and combining the grease injection process parallel to the insertion process, which reduced assembly time by 30%. 

Continuing at the same company, redesigned an insulator assembly hydraulic power unit incorporating the use of a re-gen system, which turned a 4-minute assembly cycle a 1-minute cycle.  Thus eliminating the need to purchase another assembly machine to keep up with the mold department capabilities and allowed the assembly department to run the machine one shift and keep pace with molding two-shift operation.

A result of ISO 9000 here, required all insulator products instructions to be written in conformance to the standard, which basically required a company to document what they do and do what they document in order to attain the registration.  ISO stands for International Standards Organization and instrumental for companies interested in world-class product distribution.

·        Project Engineering at Wheland Foundry with overall responsible for all shut downs and start ups, and equipment refurbishments for the gray iron automotive components plant in Warrenton, Georgia.  Consequences of that position yielded:

 

o       A mold flipper design and installation that minimized an 85% drum scrap rate,

o       An automated OD grinder operation in series with the exit conveyor, just before final diameter inspection, eliminating a manual 4 man line-off line, 24 hours a day, 6 day week operation.

o       ISO/QS9000 registration.

·        Overall maintenance responsibilities for two shifts of plant and factory equipment of 1,000,000 + square feet of manufacturing, warehouse, and shipping facilities at E-Z Go Textron in Augusta, Georgia.

·        In addition to the above other accomplishments include:

 

o       Quick change tooling in rubber molding

o       Preheating for set-up, utilized operator's “free time”, reducing non-productive set-up time by 67%.

·        Close associations and communications in Lean Manufacturing Teams working from inception thru shipment, included customer interaction, producing samples, and working as a unit to get the job done.

If implementing this type of results oriented performance is of interest to you,

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American Technical Analysis & Assistance, Inc.

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