Matthew McCoy
Peoria Hts,Il
Summary
Seeking to leverage my expertise in plant management, project management, and automation to contribute to the success of a global assembly and automation equipment management role.
Overview
30
30
years of professional experience
1
1
Certification
Work History
Senior Project Engineer
Insight Global Contract
05.2023 - Current
- Led and managed complex engineering projects from conception to completion, ensuring alignment with business objectives
- Collaborated with cross-functional teams to ensure success, fostering a culture communication and cooperation
- Provided technical guidance and expertise to project teams, contributing to the development of innovative solutions
- Utilized Lean Principles, PPAP, DFM, APQP, DFMEA, and Design of Experiments in project execution, driving efficiency and cost reduction.
Plant Manager
L & T Technical Services
01.2020 - 05.2023
- Managed a Robotics & Automation Plant, overseeing $11.3 million in design / build work from Sept
- 2022
- Implemented automation programs that saved 4.5 million dollars and repositioned 71 operators, installed 17 AGV’s, demonstrating strong cost reduction skills
- Developed business cases for automation projects, utilizing lean principles, PPAP, APQP, 5 Why’s, PFMEA, and design of experiments
- Vendor selection and follow-up
- Purchasing of components for build.
Senior Manager of Manufacturing Engineering, NPI & NPD
Ferno Washington Inc.
10.2018 - 10.2019
- Managed a lean design / build of a new FDA stretcher for use in EMT’s
- Implemented creation of processes, PFMEA, process flow diagrams
- Vendor selection and follow-up for design / build of all tooling required
- Developed business cases for offloading to vendors for work to be done in a timely manner, using lean principles to understand what was needed for the best of the program
- Utilized PFMEA, PPAP, and APQP beside IP, OP, QP.
Senior Manufacturing Engineer
Honeywell Intelligrated
12.2016 - 10.2019
- Managed a robotics and automation department overseeing 5 million dollars in programs during my tenure
- Defined all automation to be installed in the factory
- Under my direction we saved 2 million dollars per year using robot cells with an ROI of less than a year
- Developed suppliers for design / build and followed up to ensure timely delivery and minimal changes to the scope of work
- Developed the processes, SOW’s, for RFQ’s, purchase of capital equipment.
Sr. Lead Manufacturing Engineer Automation & Robotics
General Electric Aviation
05.2011 - 12.2016
- Designed lean manual and automation to accomplish welding, assembly, painting, de-burring, and inspection cells
- Utilizing lean principles, I introduced a new state of the art robotic cell for drilling 1800 close tolerance GD&T True Position holes in an aircraft assembly
- A robot cell where the robot position was being controlled by a laser tracker
- By using this system, there were savings of $13 million per year on a 3-year firm fixed contract
- Creation of cells to do Deburr, and a fully automated paint line utilizing an overhead mounted Fanuc robot on a 7th axis slave
- This was a wet line with post heaters and a bleed off system for prematurely curing the paint
- I was responsible for concept design of carts and all support tooling
- There were (2) robots on this line and the second was floor mounted to catch the additional areas requiring paint
- Process, timing, sequence of operations and throughput
- Robotic MIG and TIG weld cells
- Weld and assembly fixtures.
Manager, Manufacturing Engineering, Automation
BAE Systems
02.2009 - 05.2011
- Designed Production Lines for Government and Armored Vehicles, Process Development, Sequence of operations with timing
- Responsible for launch of new programs, creating new and optimizing existing production processes for cost reduction and improved quality, throughput and first-time yield
- Also responsible for 18 manufacturing engineers, 2 robot programmers, and a 325,000 sq
- Ft
- Manufacturing facility
- Implemented standardized launch criteria for new programs that included manufacturing and quality plans, PFMEA
- Drive lean Manufacturing Principals, Kaizen Events, 5S, and comprehensive PM (preventative maintenance) schedules for tooling and fixtures to begin at program start-up
- Planned with maintenance to order and maintain spare tool & fixture parts to limit production downtime
- IPT Team reviews of Product Designs for DFM, and DFA, Tool Designs, and Advanced Part Quality Plans to ensure adherence to PPAP, DFMEA, PFMEA, guidelines and requirements
- I introduced the use of a new Laser Tracker for inspection, set-up of production tooling, and tool calibration
- MIG manual weld fixturing, and a 1-million-dollar robot MIG cab weld cell.
Engineering Manager
Edag Productions LLC
08.2001 - 01.2009
- Design /Build and integration of 85 robot cells
- 60 were for robotic roller hemming of the Hood, Trunk Lid, and 4 Doors
- The other 25 were for miscellaneous jobs such as welding, forming, and pierce units
- Designed Tomcar Off-road Vehicle Body Shop Complete for three vehicles saving 2 million dollars on the assembly line setup
- Supplier Development, Product Development, New Program Launch, and Business Development
- Responsible for quoting and business case development for new product designs, launches, lean manufacturing process, production line designs, and timing throughput
- Designed and implemented production line to build complete Tomcar Off Roadside X Side vehicle
- I worked with suppliers in the USA to manufacture a newly designed wiring harness, MIG welded frames (3) styles, and other complex vehicle components for high quality with competitive pricing
- Working extensively with suppliers in Taiwan, China, and the USA to supply parts and assemblies of high quality and low price
- The following new products included front and rear coil over shocks, aluminum three and four core radiators, a complete exhaust system with catalytic converter, a new rack and pinion assembly, aluminum wheels, steel gas tanks, and miscellaneous machined components
- Cost saving benefits of $20 million dollars over a five-year period achieved utilizing Asian & Chinese suppliers
- Provided engineering support and direction for EPA certification programs, Robotic MIG Weld and rivet cells
- Set-up various water, air quality, and hazardous waste disposal compliance testing for government, state, or city permits
- Managed up to 45 employees in different disciplines
- Project manager for Robotic Hem Cells
- I oversaw the design, build, installation at General Motors, commissioned and brought into production.
Manager Manufacturing Engineering
J.S. McNamara Inc
08.1994 - 07.2001
Education
B.S.E. / Mechanical Engineering - Mechanical Engineering
Oakland University
Auburn, MA06.2020
Masters Certificate In Business Administration - Business
Mendoza School of Business
Notre Dame, IN12.2011
Skills
- Microsoft Office
- Catia
- Process Development
- Project Management (Automation Systems, Robotics, Manufacturing
- Supplier Development
- Envio
- Capex and Justification
- Work Instructions
- Six Sigma
- Process Generation
Accomplishments
First person in USA to do robotic roller hemming.
First person in the USA to attach a lathe bar feeder to a punch press
Certification
- GE Aviation Green Belt
- Master’s Certificate in Management and Leadership
- Continuous Quality Improvement, Project Management, and Catia
Timeline
Senior Project Engineer
Insight Global Contract
05.2023 - Current
Plant Manager
L & T Technical Services
01.2020 - 05.2023
Senior Manager of Manufacturing Engineering, NPI & NPD
Ferno Washington Inc.
10.2018 - 10.2019
Senior Manufacturing Engineer
Honeywell Intelligrated
12.2016 - 10.2019
Sr. Lead Manufacturing Engineer Automation & Robotics
General Electric Aviation
05.2011 - 12.2016
Manager, Manufacturing Engineering, Automation
BAE Systems
02.2009 - 05.2011
Engineering Manager
Edag Productions LLC
08.2001 - 01.2009
Manager Manufacturing Engineering
J.S. McNamara Inc
08.1994 - 07.2001
B.S.E. / Mechanical Engineering - Mechanical Engineering
Oakland University
Masters Certificate In Business Administration - Business
Mendoza School of Business
- GE Aviation Green Belt
- Master’s Certificate in Management and Leadership
- Continuous Quality Improvement, Project Management, and Catia
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