Paul A. Shaffstall
Wooster,OH
Summary
Dynamic Senior Manufacturing Quality Engineer with a proven track record at Schaeffler Transmission Systems, excelling in quality assurance and process improvement. Expert in root cause analysis and training, driving significant cost reductions and enhancing product launches. A collaborative leader committed to delivering exceptional results in high-precision manufacturing environments.
Overview
28
28
years of professional experience
Work History
Senior Manufacturing Quality Engineer
Schaeffler Transmission Systems
Wooster, USA
01.2017 - Current
- Delivered quality engineering support for two value stream lines, ensuring compliance with quality standards and enhancing product reliability.
- Led quality launch activities for new product line, facilitating successful project completion and timely market introduction.
- Provide training and mentoring for associate quality engineers.
- Coordinated Customer Quality support for PPAP submissions, streamlining process and ensuring alignment with customer requirements.
- Conduct investigations into quality issues and implement solutions.
- Schaeffler manufactures high-precision components and systems for engine, transmission and chassis applications for commercial and non-commercial vehicles.
Manufacturing Quality Engineer
Schaeffler Transmission Systems
Wooster, USA
05.2017 - 09.2019
- Delivered quality engineering support for assembly and machining areas, enhancing product consistency.
- Implemented Q-DAS SPC data collection software at all department work centers replacing an aging SPC data collection software.
- Facilitated Customer Quality through timely and accurate PPAP submissions, ensuring compliance and customer satisfaction.
- Conduct investigations into quality issues and implement solutions.
- Developed quality documentation (Process Flows, Control Plans, PFMEAs) for new product launches, establishing clear quality standards.
- Specify and procure gaging and measurement systems for new products as well improvements for existing production.
- Provide training and mentoring for associate quality engineers.
- Proficient in SAP, QS-STAT Statistical Software and Minitab Statistical Software.
- Schaeffler manufactures high-precision components and systems for engine, transmission and chassis applications for commercial and non-commercial vehicles.
Manufacturing Engineer
Bettcher Industries
Birmingham, USA
01.2014 - 01.2017
- A leading developer and manufacturer of innovative precision cutting and trimming tools for the food processing and industrial manufacturing sectors. The company also manufactures food preparation equipment for restaurants and commercial kitchens in the food service industry.
- Led project to implement tooling vending machines, enhancing inventory management and tool usage tracking, resulting in savings exceeding $35K.
- Designed and optimized fixtures using SolidWorks and CAD, improving production accuracy and reducing setup time.
- Developed standardized processes for new product releases and engineering changes, ensuring consistency and efficiency.
- Developed routing standards to accurately cost out heat treat operations for all products.
- Provided shop floor support in both machining and assembly areas for laser and heat treating.
- Proficient in using Infor PLM and SyteLine business systems.
2nd Shift Manufacturing Engineer
Olympus Surgical Technologies America
Norwalk, USA
01.2012 - 01.2013
- Supported second shift machine shop, supervising 12 hourly employees to ensure smooth operations.
- Resolved manufacturing issues during second shift operations.
- Retrofitted the Laser Marking Machine, saving more than $125K by not having to purchase a new machine.
- A precision technology leader, creating innovative opto-digital solutions in healthcare, life science, and consumer electronics products. Olympus supports the work of medical professionals by providing advanced, minimally invasive therapeutic and diagnostic technologies to improve the quality of patient care around the globe.
Tooling Engineer
Rotek Incorporated
Aurora, USA
01.2010 - 01.2012
- Reviewed product design drawings to confirm availability of tools required for part production, including cutting tools, gear cutting tools, and induction hardening tooling.
- Managed tool testing process, achieving cost reductions through effective resource allocation.
- Investigated and implemented new tooling technology.
- Collaborated with tooling vendors on improvement projects to enhance tooling performance.
- Managed monthly tooling budget to ensure purchases did not exceed the budget or were under budget.
- The North American leading manufacturer of slewing bearingss, including ball and roller slewing bearing, and wire-race slewing bearings. Rotek is a market leader for seamless forged steel and non-ferrous metal rings.
Manufacturing Engineer in the In-Sourcing Group (Contract)
Swagelok Company
Highland Heights, USA
01.2009 - 01.2010
- Developed in-sourcing processes for parts at Highland Heights facility, streamlining production capabilities.
- Developed routings for new parts that were in-sourced. This included developing tooling and gauging as well as estimating machining time and determining capacity.
- Developed routings, BOMs, and machining setup sheets as well as selected appropriate tooling and reviewed Quality Plans.
- Developed fluid system solutions, delivering products, assemblies, and services across industries including research, instrumentation, pharmaceuticals, oil and gas, power, petrochemicals, alternative fuels, and semiconductors.
Manufacturing Engineer
Ridge Tool Company
Elyria, USA
01.1998 - 01.2009
- Global leader in the manufacturing and development of professional plumbing and hand tools serving the commercial construction, oil & gas, and residential markets.
- Led manufacturing engineering team on new product development project, establishing manufacturing processes for successful product launch.
- Completed a Six Sigma project that identified the root cause of non-conformance issue on a key product line. A new inspection method was developed to ensure measurement accuracy.
- Implemented new manufacturing processes and improved vision measurement technique on threading dies, extending grinding wheel life and saving $15,000.
- Improved throughput and lead time on low volume dies by creating semi-finished hardened blanks, reducing lead time to five days or less.
- Converted resin bond grinding wheels to CBN plated wheels, achieving savings of $1,500 per wheel.
- Managed two machining areas which included: CNC grinding and conventional grinding, CNC turning centers, and CNC machining centers. Machined ferrous and non-ferrous materials for tool, fixture, and gauge design.
- Developed and de-bugged CNC programs using SurfCAM CNC software.
- Developed assembly cell and assembly instructions for new products.
- Designed gauges and fixtures using Solid Works CAD system for new and existing products.
- Determined and documented gauging requirements for new and existing products.
- Led purchased and installation of an automated laser marking system that improved productivity and output for a key company product line.
Education
Bachelor of Science (BS) - Mechanical Engineering Technology
Cleveland State University
Cleveland, OH01.1998
Associate of Applied Science (AAS) - Manufacturing Engineering Technology
Lorain County Community College
Lorain, OH01.1996
Skills
- Quality Engineering
- Manufacturing Engineering
- Lean Manufacturing
- Six Sigma Green
- Root cause analysis
- Quality Assurance
- Process Improvement
- FDA Requirements
- IATF Requirements
- Project Management
- Capital Equipment Installation
- Automotive Processes
- Medical Devices
- Product Launch
- Collaborative Leaders
- Cost Reduction Strategies
- 5S
- Kaizen
- Training and mentoring
- Research and Development
- Problem solving
- Problem Resolution
- Team Player
- MS Project
- MS Office
- Industrial Engineering
- MS Office
- MS Project
Professional Development
- Six Sigma Green Belt Certification, Emerson Electric, St Louis, MO, 01/01/07
- Microsoft Project Training, Emerson Electric, St Louis, MO, 01/01/06
Timeline
Manufacturing Quality Engineer
Schaeffler Transmission Systems
05.2017 - 09.2019
Senior Manufacturing Quality Engineer
Schaeffler Transmission Systems
01.2017 - Current
Manufacturing Engineer
Bettcher Industries
01.2014 - 01.2017
2nd Shift Manufacturing Engineer
Olympus Surgical Technologies America
01.2012 - 01.2013
Tooling Engineer
Rotek Incorporated
01.2010 - 01.2012
Manufacturing Engineer in the In-Sourcing Group (Contract)
Swagelok Company
01.2009 - 01.2010
Manufacturing Engineer
Ridge Tool Company
01.1998 - 01.2009
Bachelor of Science (BS) - Mechanical Engineering Technology
Cleveland State University
Associate of Applied Science (AAS) - Manufacturing Engineering Technology
Lorain County Community College