Douglas Gibson
Dana Corporation
Jackson,USA
34
years of professional experience
Manufacturing engineering professional prepared for this role with strong expertise in process optimization, quality control, and project management. Known for fostering team collaboration and delivering results in fast-paced environments. Skilled in lean manufacturing, Six Sigma principles, and CAD software. Adaptable to changing needs and reliable in driving continuous improvement initiatives.
Work History
Senior Manufacturing Engineer
26 Years 11 Months- Senior Manufacturing Engineer since 2007.
- Lead Engineer & Capital Manager in the $25 million capital equipment project for the addition of 4 new Drive Shaft lines and one line transferred from another Dana facility. I wrote all capital purchase orders and forecasting capital spend by month for the project. I am the primary contact for working with the different machine manufacturers and machine acceptance at the vendors facility and the plant. I oversaw laying out the new equipment in the plant and working with the Engineering Manager to facilitate plant improvements for the new Tier 1 lines. I worked with the production launch team to build and send test parts for Production Validation testing.
- Capital Manager for the Humboldt plant since 2019. I am accountable for writing and justifying all Capital Appropriation projects.
- Lead Engineer in the $12 million capital equipment project in 2021. Responsible for writing Scope of Work, procuring vendor quotes, writing capital appropriation requests, working with purchasing for writing the Schedule A (Vendor Contracts), writing purchase orders, collaborating with vendors on design review approvals, meeting regularly to discuss issues and answer questions.
- Resident engineer for the Humboldt plant for all new housing part numbers and Engineering Process changes. Determine if the Humboldt plant was set up to make this new part number. If not, design tooling in 3D (SolidWorks) for all required processes on the production line.
- Facilitated weekly meetings with Corporate Engineering to discuss Engineering Work Orders in the Humboldt, TN facility. with Corporate Engineering to discuss Engineering Work Orders in the Humboldt, TN facility.
- Updated and optimized plant layouts at the Dana Humboldt facility to improve workflow and efficiency. at the Dana Humboldt facility.
- Led Kaizen teams on improving productivity (setup reduction, process improvements).
- Responsible for all process prints in the Humboldt plant.
- Created CCL (Competency Check Lists) for all processes in the Humboldt plant.
- Created work instructions for all equipment used in the plant.
- Troubleshooting all robot issues in the plant. Have experience with both Kuka and Fanuc robots (welding and material handling) (40+ robots total).
- Lead engineer for plant optimization projects (re-layout of production equipment lines for line balancing and improved flow, bracket weld optimization projects). Worked with in-house maintenance and outside contractors to meet project deadlines.
- Responsible for new product startups within the plant including a $3.5 million capital investment for retooling and adding new equipment.
- Responsible for completing an $850,000 robotic welding project which included (1) debugging/troubleshooting and installing the new robotic welding system into the production line, (2) laying out production equipment which maximized material flow, (3) writing programming code for this new robotic welding system, (4) training operators/set-up personnel to teach points to weld various parts, (5) writing instructions for operators/set-up personnel to use in operating/troubleshooting the welding system, (6) procuring new motor/gearbox combination to double the rotation speed of our external axis, (7) assisting operators/set-up personnel in correction quality issues.
- Responsible for a $600,000 upgrade on one of our Friction Welders. This included obtaining quotes, writing appropriation requests for funds, justifying projects, and overseeing installation.
- Responsible for a $150,000 upgrade of an existing robotic system to Fronius Twin Wire.
- Responsible for a $120,000 upgrade on our 2 Trio Machines from Relay Logic to PLC.
- Responsible for the $100,000 upgrade to a Twin Tandem Welding System on a Cloos Robotic Welding System.
- Responsible for installation of four other robotic systems into our production area including (1) working with vendors to coordinate activities during installation, (2) teaching operators/set-up personnel how to operate robotic systems, (3) writing work instructions for running the systems, (4) writing detailed steps for troubleshooting the robotic systems.
- Ability to program Cloos and Kuka robots. Have worked with Fanuc robots in our facility.
- Acquired quotes, created appropriation requests, justified project funding, led installation, start-up, and troubleshooting for another $350,000 robotic welding system.
Manufacturing Engineer
3 Years 4 Months- Manufacturing Engineer in the Sports Business Area. Directed new product launches, crafted tooling and fixturing designs for manufacturing, secured quotes, composed appropriation requests for funding, justified projects, managed installation, startup, and troubleshooting of new and retrofitted equipment, organized production equipment layouts to enhance material flow, recorded and updated all routings and bills of materials in my business area, managed the Aberdeen plant layout, resolved ongoing production issues related to equipment and tooling, and drafted work instructions and lockout/tagout instructions for the equipment in my business area.
- Led cross-functional teams to improve manufacturing processes and enhance product quality.
- Developed and implemented process improvements, resulting in increased operational efficiency.
- Conducted root cause analysis for production issues, driving corrective actions to minimize downtime.
Process/Manufacturing Engineer
2 Years 2 Months- Led process engineering for welding, press, and paint departments. Engineered solutions for Uniframe Table Production Area. Executed procurement, installation, and troubleshooting of new robotic welding systems along with similar responsibilities in my current role.
- Led cross-functional teams to enhance manufacturing processes and improve product quality.
- Developed and implemented process improvements resulting in increased operational efficiency.
- Mentored junior engineers, fostering a culture of continuous learning and innovation.
Process Engineer
1 Year 7 Months- Process Engineer over cargo shade products for Chrysler, Ford, General Motors, Honda, Isuzu, and Toyota. My responsibilities included (1) planned new program launches, determining equipment, manning, and layout requirements, (2) planning and implementing sample builds of these new products, (3) ensuring the quality of raw materials entering and finished goods leaving our production area, (4) designed Poka-Yoka fixtures to prevent defective cargo shades from reaching customers, (5) developed inspection procedures between workstations, enhancing quality control in current position at Dana Corporation.
- Led process optimization initiatives, enhancing production efficiency and reducing waste in manufacturing operations.
- Developed and implemented standardized work instructions to ensure compliance with industry safety regulations.
- Analyzed production data to identify bottlenecks, facilitating continuous improvement in operational workflows.
Education
Bachelor of Science - Industrial Engineering
University Transfer Program - Pre-Engineering
Skills
Robotic programming
Software proficiency
Team leadership
Training and mentoring
Detail oriented
Hardworking and dependable
Written communication
Timeline
Senior Manufacturing Engineer
Dana Corporation
09.1999 - CurrentRead More
Manufacturing Engineer
Tenneco Automotive/Walker Manufacturing
05.1996 - 09.1999Read More
Process/Manufacturing Engineer
Krueger International
03.1994 - 05.1996Read More
Process Engineer
TAKATA – Irvin Automotive Products
08.1992 - 03.1994Read More
Meridian Community College
University Transfer Program from Pre-Engineering
Read More
Mississippi State University
Bachelor of Science from Industrial Engineering
Read More