Daniel Sims

Experienced Advanced Manufacturing Engineer and Launch Manager with 12 years of expertise in the manufacturing industry. Proven track record in successfully managing new product launches, optimizing production processes, implementing lean methodologies, and driving continuous improvement initiatives. Currently employed at WKW Automotive, seeking new opportunities to apply skills and contribute to the advancement of manufacturing technologies in a dynamic organization.

Project Title: Maverick Engine Block Line

Project Duration: 01/15/2019 - 11/30/2020

Project Overview: Guided the design, installation, and launch of an engine block production line, seamlessly transitioning from manual prototyping and low initial volumes to full automation for high-volume production within a project Capex budget of $80 million.

Project Scope: This project encompassed the end-to-end design, installation, and operational optimization of an engine block production line. The scope included the initial phase of manual equipment operation for prototyping and low-volume production, followed by the implementation of intermediate automation to facilitate a smooth volume ramp-up. The final phase involved the establishment of a fully automated production line capable of handling a weekly volume of 6,000 engine blocks, ensuring precision and efficiency throughout the entire process.

My Role and Responsibilities: As the Advanced Manufacturing Engineer, I spearheaded critical aspects of the project. This included collaborating with the customer to define volume and equipment specifications, liaising with machine builders to design the necessary equipment, executing on-site equipment deployment, conducting comprehensive capability studies, rigorously managing program budgets, and serving as the primary point of contact, ensuring seamless coordination and communication throughout the project's lifecycle.

Challenges Faced: Addressed obstacles including delayed Capex approvals by collaborating with machine builders to initiate the project creatively. Managed limited parts supply by devising a mutually beneficial timeline with suppliers. Successfully resolved quality issues with incoming parts through supplier collaboration and quality improvement measures.

Technologies/Tools Used: Leveraged a suite of advanced technologies, including Multi-spindle 5-axis CNC machines, automated assembly equipment, leak test systems, 7th-axis robots, linear gantry systems, vision inspection systems and performed Cmk and Cpk analysis to ensure precision and efficiency in project execution.

Results and Outcomes: Effectively delivered the project on schedule, within budget, and in full compliance with all program requirements.

Lessons Learned: Valuable lessons were learned from this project, including the importance of enhancing RFQs to proactively account for unforeseen supplier issues. Additionally, the significance of securing wholehearted commitment from all team members was underscored, promoting cohesion and productivity. Finally, the project emphasized the need to meticulously document all agreements and details, ensuring clarity and accountability in project management and execution.

Project Team: Program Manager, Process Engineer, Industrial Engineer, Quality Engineer, Plant Maintenance Engineer, Casting Engineer.

Project Status: Completed

Project Title: Lift gate and Longitudinal Member Lines

Project Duration:11/15/2020 – 12/31/2022

Project Overview: Oversaw the design, installation, and commissioning of production lines for Lift gates and longitudinal members, orchestrating the shift from manual operation during prototyping and low initial volumes to full automation, all within the confines of a $100 million Capex budget

Project Scope: This project entailed comprehensive design, installation, and operational enhancement for the production lines of Lift gates and longitudinal members. The project's scope initially involved manual equipment operation for prototyping and low-volume production, followed by a strategic transition to intermediate automation for a streamlined volume increase. In the project's culmination, fully automated production lines were established to ensure precision and efficiency in accommodating the required production volumes.

My Role and Responsibilities: As the Advanced Manufacturing Engineer, I played a pivotal role in this project. This included collaborating with the customer to define volume and equipment specifications, working with machine builders to design necessary equipment, overseeing on-site equipment deployment, conducting thorough capability studies, managing program budgets, and serving as the primary point of contact for seamless project coordination and communication.

Challenges Faced: Addressed obstacles including delayed Capex approvals by collaborating with machine builders to initiate the project creatively. Managed limited parts supply by devising a mutually beneficial timeline with suppliers. Successfully resolved quality issues with incoming parts through supplier collaboration and quality improvement measures.

Technologies/Tools Used: Utilized an array of cutting-edge technologies, including 3D auto-straightening machines, Robotic auto grinding equipment, Multi-spindle 5-axis CNC machines, robotic assembly equipment, 7th-axis robots, linear gantry systems, SPC systems, vision inspection systems and performed Cmk and Cpk analysis to ensure precision and efficiency in project execution.

Results and Outcomes: Successfully steered the project to the 85% completion milestone before departing the company for a new opportunity. The project remained on schedule, with a slight budget overrun, and continued to meet all program requirements even after my departure.

Lessons Learned: Valuable lessons were learned from this project, including the importance of enhancing RFQs to proactively account for unforeseen supplier issues. Additionally, the significance of securing wholehearted commitment from all team members was underscored, promoting cohesion and productivity. Finally, the project emphasized the need to meticulously document all agreements and details, ensuring clarity and accountability in project management and execution.

Project Team: Program Manager, Process Engineer, Industrial Engineer, Quality Engineer, Plant Maintenance Engineer, Casting Engineer.

Project Status: Completed

Project Title: OEE Optimization

Project Duration: 1/15/2024 – 2/16/2024

Project Overview: Oversaw the optimization of a stretch bending, CNC machining and Auto-polishing process which historically ran 60% OEE or below.

Project Scope: This project required a comprehensive overview of process flow, process design and deep diving the equipment tooling and programming.

My Role and Responsibilities: Collaborated with Production management, Quality Engineer, Process engineer and production team members to organize efforts and drive a plan to improve the process efficiency. 

Challenges Faced: Process deviations, non-conformity among current production staff and quality technicians and less than optimal equipment tooling design.

Results: My team achieved an average weekly OEE of 92% and a 55% increase in weekly production by optimizing process flow, machine programming, tooling optimization and creating a more lean and thorough training process for the operations team.