Experience

Mid-West Forge Corporation

• United States
• Automotive
• 1 - 100 Employee

• Engineering Manager

  • Jun 2020 - Present

  Medina County, Ohio, United States



Howmet Aerospace

• United States
• Aviation and Aerospace Component Manufacturing
• 700 & Above Employee

• Smart Manufacturing Manager

  • Aug 2016 - May 2020

  Cleveland, Ohio, United States • Global responsibility for Smart Manufacturing for Alcoa wheels business • Led Smart Manufacturing Center of Excellence with 6 direct reports • Implemented OSI PI historian with MES functionality on forge line as the first pilot line for the Alcoa Wheels business • Copied this implementation to 4 other press lines with all projects completed on time and under budget • Developed digital metrics to track effectiveness of Smart Manufacturing cycle time tools • Led Use Case campaign… Show more • Global responsibility for Smart Manufacturing for Alcoa wheels business • Led Smart Manufacturing Center of Excellence with 6 direct reports • Implemented OSI PI historian with MES functionality on forge line as the first pilot line for the Alcoa Wheels business • Copied this implementation to 4 other press lines with all projects completed on time and under budget • Developed digital metrics to track effectiveness of Smart Manufacturing cycle time tools • Led Use Case campaign to increase impact of Smart Manufacturing • Used of OSI PI tools to drive improvements including PI Notifications, Datalink, ProcessBook, PI Vision, and PI Coresight • Leveraged best practice sharing between locations to drive improvements • Supported Smart Manufacturing implementation in casting, machining, and AWPM. • Presented Smart Manufacturing information in multiple forums including Plant Manager’s Summit, Team NEO -Smart Devices and Systems Cluster (Keynote speaker), and CEO visits Show less



Alcoa

• United States
• Mining
• 700 & Above Employee

• Sr. Staff Process Engineer

  • Sep 2013 - Aug 2016

  Cleveland/Akron, Ohio Area Responsible for process improvements and cost reductions in truck wheel forging. Key accomplishments include: -Development of truck wheel forging on presses 50% smaller than standard truck wheel production to prevent idling auto wheel press lin -Cycle time improvements on all Cleveland press lines ranging from 8% to 28% worth over $5,000,000 annually -Forging and spinning technology transfer to Monterrey, Mexico plant to produce new lightweight truck wheels -Implemented flowforming… Show more Responsible for process improvements and cost reductions in truck wheel forging. Key accomplishments include: -Development of truck wheel forging on presses 50% smaller than standard truck wheel production to prevent idling auto wheel press lin -Cycle time improvements on all Cleveland press lines ranging from 8% to 28% worth over $5,000,000 annually -Forging and spinning technology transfer to Monterrey, Mexico plant to produce new lightweight truck wheels -Implemented flowforming process on 3 new machines including specification development, factory runoff and CNC programming, improving productivity by 15% -Best practice transfer of lubrication system to reduce lube gun costs and lube usage

• Production and Maintenance Superintendent

  • Dec 2012 - Sep 2013

  Cleveland, Ohio, United States Led team of 6 salaried supervisors and 45 hourly operators and technicians on 2 lines with annual revenue of $100M. • Drove productivity improvements of 13% through OEE emphasis • Raised employee engagement score on Global Voices Survey from 57% to 60% by building a culture of dignity and respect.

• Forging, Spinning, and Tooling Manager/Sr. Staff Process Engineer

  • Feb 2000 - Dec 2012

  Cleveland, Ohio, United States Design • Provided guidance to die designers working on new jobs and improvements to existing forgings • Developed tooling and processes to produce the first 20”, 22” and 22.5” wheels in Y-Plant • Developed new 19 ½” truck wheel forging technique to reduce forged weight by 27 lb. (2000) Process • Implemented yield improvements resulting in annual savings of $900K (2011) • Eliminated pre-machine operation resulting in an annual savings of $400,000 (2010) • Led development… Show more Design • Provided guidance to die designers working on new jobs and improvements to existing forgings • Developed tooling and processes to produce the first 20”, 22” and 22.5” wheels in Y-Plant • Developed new 19 ½” truck wheel forging technique to reduce forged weight by 27 lb. (2000) Process • Implemented yield improvements resulting in annual savings of $900K (2011) • Eliminated pre-machine operation resulting in an annual savings of $400,000 (2010) • Led development efforts for 18 new forgings resulting in 41 product launches in one year (2006) • Successfully transferred forged feature wheels and adapted process technology from Lebanon, VA plant to run in Cleveland flow path (2009) • Used Six Sigma tools to reduce forge scrap on 20” DCX wheels from 3% to 0.7% (2007) • Developed CMM inspections for forgings for improved correlation to scrap (2011) • Participated in Kaizen event to reduce die change time in X-Plant (2008) Global • Led Global Best Practice Team for Forging (2011-2012) • Provided forging process support to plant in Monterrey, Mexico (2010-2012) • Supported forging start up in Belaya Kalitva, Russia for auto and truck wheels (2006) CNC Programming • Developed tools for programming CNC flow forming machines including AutoLisp programs to convert CAD geometry to CNC code and simulate roller movement (2000-2012) • Trained new CNC engineer in spinner programming and trouble shooting (2012) • Wrote and developed CNC spinner programs for over 90 forgings (2000-2012) • Developed method to verify correct spinner set-up (2001) Leadership • Managed scrap reduction projects in forging, machining, and polishing resulting in $1.9M in savings (2011) • Supervised engineers and designers involved in new product launch and production support • Completed ALCOA’s Leadership Planning Program at the CWRU’s Weatherhead School of Management (1999)

• Supervisor of Product and Process Analysis

  • Feb 1996 - Feb 2000

  Cleveland, Ohio, United States • Determined press requirements and eliminated forging indications using DEFORM simulations • Worked with process engineers and die designers to reduce weights of forging resulting in an annual savings of 12,500,000 lbs of aluminum • Designed stylized aluminum wheels for heavy and light truck applications • Performed finite element analysis using ANSYS to determine fatigue performance • Increased accuracy of FEA using strain gage and pressure sensor data to correlate… Show more • Determined press requirements and eliminated forging indications using DEFORM simulations • Worked with process engineers and die designers to reduce weights of forging resulting in an annual savings of 12,500,000 lbs of aluminum • Designed stylized aluminum wheels for heavy and light truck applications • Performed finite element analysis using ANSYS to determine fatigue performance • Increased accuracy of FEA using strain gage and pressure sensor data to correlate results • Reduced weight of highest volume truck wheels while improving fatigue performance • Managed prototypes, manufacturing, and field testing of light weight wheels

• Plant Engineer - Design

  • Jan 1991 - Feb 1996

  Cleveland, Ohio, United States Design work to support large forge plant using AutoCad • Completed design projects for equipment in forge plant including new equipment design, access ladders and platforms, fume exhaust systems, and plant layouts • Calculated stresses in existing equipment and new designs • Coordinated efforts to reduce plant wide noise levels and performed noise level simulations