Josh — Project Engineer

Project Lead for improvement studies, Six Sigma Analysis, and elemental time studies.

Five years as a Field Service Engineer installing and maintaining precision electronic measurement systems for cam shaft, crank shaft, piston, engine block, and many other precision cast parts manufactured at Ford, Chrysler, Honda, Toyota, Nissan, GM, and Saturn manufacturing facilities.

-Managed several projects to update Nissan Canton HMIs with more informative troubleshooting animations and alerts. -Created PLC logic for fault animations in RSLogix 5000, GE Proficy, and Omron PLC environments. -Created screens with GE Cimplicity that streamlined the fault recovery activities as well as increase the efficiency of the operators. -Applied a consistent theme across all screens including existing to reduce error when navigating to the various areas each HMI controlled. -Managed field survey activities where several engineers would physically validate inputs, drives, motion automation, and all data driven movement related animation. -Primary Nissan customer contact for Mississippi customers. -Performed cold calls on customers in our area to establish relationships that lead to jobs.

- Managed 25 Production associates, 10 Maintenance Technicians, two Maintenance Supervisors, and two Production Supervisors who supported four fast paced and highly automated manufacturing lines. - Project Lead for improvement studies, Six Sigma Analysis, and elemental time studies. - Supervised implementation and development of all programming and error proofing systems. - Rockwell Automation's RSLogix 5, 500, and 5000 programming environments. - Experience with Banner, DVT, and Allen Bradley Vision systems. - Experience with DH+, ControlNet, DeviceNet, and Ethernet controls networking design. - Developed custom data collection methods to assist in statistical process control by writing Visual Basic code integrated with Microsoft Excel. - Managed the launch of several new model instrument panels and interior components for Nissan and Acura by coordinating the receipt of new control systems and integrating with existing data collection methods and communication networks.

- Installed automated end of line inspection, in-process inspection, and interim inspection methods for several engine part OEMs. - Developed statistical data collection methods to measure production performance in real time while automatically adjusting tools based on trend calculations and automatic tool wear analysis. - Troubleshot system integration issues through the use of PLC ladder logic and mechanical engineering knowledge. - Responsible for the training of engineers, technicians, & operators at customer sites for maintenance and programming of all systems. - Custom digital/analog machine interface design on-site for Honda, Ford, Nissan, Saturn, Toyota, and Chrysler. - Primary customer contact for all customers within a four-hour radius of Nashville, TN, the top sales region for 2004 & 2005. - Worked from a home office while traveling 80%. - Primary gauging specialist for several product launches with Honda, Ford, Nissan, GM, Chrysler, Johnson Outboards, and Saturn.

- Worked closely with RD&E, Production, Maintenance, and Process Engineering to solve critical to quality issues. - Performed primary, secondary and standard reference testing, calibration, preventive maintenance and repair of electronic, physical dimensional, and laboratory standards. - Managed the Radiological Source Program for two calibration sites in accordance with the Nuclear Regulatory Commission license. - Managed workload distribution obtaining a 99% customer equipment readiness rate. - Managed and trained a team of ten technicians as to their jobs and responsibilities in advanced troubleshooting, operating and maintenance of precision test equipment. - Provided engineering management support by assisting metrology & calibration technicians, in the completion of complex calibrations and repairs. - Performed component level repair training using detailed schematic diagrams, manufactures written theory of operation, and military written procedures.

-Managed a group of engineers and technicians during the completion of several tool assembly automation projects. -Created all concept designs for automation projects. -Specified equipment necessary to purchase for automation projects. -Removed significant amounts of labor from the processes and increased the profit margins for several of the high-volume tools. -Managed the creation of seven assembly lines for a new product launch. -Developed automation for new products. -Have led and participated in several successful kaizen/lean events. -Work with product engineers on alternate designs for new product development. -Train junior engineers to program PLCs, Robots, Torque Analyzers, and several other pieces of technology. -Created an intern position to begin attracting local electrical and mechanical engineering students to our facility. -Write all Capital Approval Requests for the purchase of new equipment plantwide. -Work closely with finance to ensure budgets are adhered to during the development of automated systems. -Served as the point for maintaining capital spending tracking and accuracy for the Jackson Mississippi facility.

- Manage DAN Technology grind and polish cells with pressure transducer feedback adjustment. -Manage Motoman Welding cell with Adaptive power supplies, Servo-Robot Laser tracking, Comarc, and touchsense. - FANUC and Motoman robot and PLC programmer/trainer. - Project Manager for automated grind, polish, and welding cells that significantly changed the methods for processing the core cooking products. Ergonomics and labor reduction were the key driving factors that led to the approval of this five year project. - Developed, specified, negotiated, managed, implemented, and programmed three robotic cells in one project. -Manage technical aspects of the implementation of a 3 million dollar automated sheet metal fabrication line from installation to full production. - Use industrial engineering time study techniques to increase the throughput of the existing manually loaded press breaks and cutting tools. - Develop standard tool kitting for press breaks to enable predictive job flow. - Led a project to increase Press Brake efficiency by 60% through the use of upgraded tooling and clamping systems. - Implemented a networked press brake program management system that enables press brake operators to share part programs between machines.

- Performed high pressure co-axial and tri-axial load, strain, and stress testing of various materials to develop weapons systems such as the Bunker Buster Bomb used in Desert Storm. - Assisted in the analyzing of test data and performed computer simulated tests on SGI Workstations that ran in parallel with the world's largest bank of Cray Supercomputers. - Developed methods to organize and share data across several offices through the use of UNIX and X-Windows operating environments. - Acted as primary technician for the GeoStaff research boat, which was the first system ever developed capable of classifying soil strengths on the ocean floor with water depths up to 30 feet. - Assisted engineering staff with report development when projects were complete. - Assisted with model building for scale testing during projectile shape development projects.