DILLON STAWIARSKI

Detail-oriented Manufacturing Process Engineer with expertise in Lean Manufacturing, CNC machining, tooling/fixturing design, and production optimization. Experience working in aerospace, defense, and industrial manufacturing, ensuring high-quality, cost-effective, and producible solutions for complex assemblies. Skilled in technical data package development, process flow optimization, and root cause analysis. Adept at collaborating with cross-functional teams, including engineering, quality, CNC programming, and supplier management, to drive continuous improvement and operational efficiency.

Seeking to leverage my expertise in process engineering, Six Sigma methodologies, and manufacturing workflow optimization to support high-volume production in the defense sector.

Boeing – Aerospace & Defense Manufacturing

Technical Data Package (TDP) Optimization & Supplier Support

• Developed and maintained over 50+ Technical Data Packages (TDPs) for F/A-18, F-15, and MQ-25 spare parts, ensuring manufacturability and compliance with AS9100 standards.
• Identified common design and machining issues affecting suppliers and worked with engineering teams to implement cost-effective modifications, reducing supplier RFQ turnaround time by 25%.
• Assisted in troubleshooting supplier manufacturing issues, providing GD&T-compliant design feedback and machining recommendations to improve fabrication consistency.

CAD-Driven Tooling & Fixture Design

• Designed and optimized tooling and fixturing solutions using Siemens NX and SolidWorks to improve machining stability and reduce setup time by 30%.
• Created 3D CAD models and engineering drawings for custom clamping and work-holding solutions, ensuring tight tolerances within ±0.001” and reducing machining defects by 18%.
• Assisted in transitioning manufacturing documentation from SolidWorks to Siemens NX, ensuring seamless integration with Boeing’s new digital manufacturing workflow.

Machining Process Optimization & Lean Implementation

• Conducted machining feasibility assessments for new aerospace components, identifying potential constraints and recommending optimized cutting strategies, reducing fabrication lead times by 15%.
• Collaborated with CNC programmers to optimize toolpaths, feeds, and speeds, reducing cycle times by 15% while maintaining high-precision tolerances.
• Applied Lean manufacturing principles such as Value Stream Mapping (VSM) and 5S, improving production efficiency and workflow standardization.

Hussmann – High-Volume Manufacturing & Process Improvement

Lean Manufacturing & Standard Work Implementation

• Led Kaizen events and 5S initiatives, reorganizing workstations, tools, and material flow to reduce non-value-added movement by 25% and increase productivity.
• Developed and standardized Standard Work Instructions (SWIs) for assembly processes, improving consistency and reducing defect rates by 12%.
• Designed and implemented training programs for new operators, decreasing onboarding time by 30% while ensuring compliance with production standards.

Time Studies, SMED, & Changeover Reduction

• Conducted time-motion studies and Single-Minute Exchange of Die (SMED) analysis, identifying bottlenecks in machine changeovers.
• Implemented quick-change fixturing systems and redesigned changeover processes, reducing machine downtime from 40 minutes to 25 minutes (38% reduction).
• Developed step-by-step SOPs (Standard Operating Procedures) for operators, improving consistency and increasing machine uptime by 20%.

Kanban-Based Inventory Optimization

• Designed and implemented a Kanban system for high-demand refrigeration components, improving inventory management and reducing stockouts by 40%.
• Conducted ABC inventory analysis to classify parts by demand frequency, ensuring JIT (Just-in-Time) inventory replenishment and freeing up 20% of warehouse storage space.

Bayer – Process Optimization & Six Sigma Projects

Process Optimization & Waste Reduction

• Conducted a Six Sigma-based analysis to reduce seed loss in packaging operations by 8%, identifying root causes through Pareto charts and Fishbone Diagrams.
• Implemented process standardization measures, improving crop yield by 12% and reducing material waste-related costs.

Production Flow & Automation Strategy

• Created process flow charts and optimized material delivery scheduling, reducing lead times for packaging materials by 15%.
• Assisted in evaluating automation opportunities for seed processing operations, identifying machine optimizations that improved overall process reliability.