Seunghwan Charlie Cha
Peachtree City,United States
Summary
Production Engineering/Maintenance Management. Specialized in mass, lean manufacturing, fully automated serial assembly line. Analyze OEE and increase productivity. Improve machine and quality issues. Establish CAPEX and operation budget based on OEE, MTTR and MTBF. Establish spare part system with system development team. Experience with SAP, ERP, MES system to implement to production line.
Skill: Autocad, Inventor, Vision Program, Micro Office, CNC Program, Robot programing(Yaskawa, Fanuc), Servo Press, AMR Operation, Welding(Tig and Laser) Machine Operation.
Overview
13
13
years of professional experience
1
1
Certification
Work History
Maintenance Manager
Hyundai MOBIS North America Electrified Powertrain, LLC
10.2024 - 10.2025
- Led maintenance operations for EV motor and stator production in a high-volume automated plant, while actively handling daily troubleshooting and line recovery.
- Provided direct maintenance support for servo presses, Yaskawa robots, EOL testers, Atlas Copco nut runners, AMRs, and vision inspection systems.
- Supported and maintained 88+ station automated assembly lines, stator forming and welding systems, and warehouse automation, responding on-site during major downtime events.
- Performed root cause analysis and implemented corrective and preventive actions for repeated and critical equipment failures.
- Analyzed and troubleshot PLC programs to identify logic, sensor, and interlock-related issues.
- Developed and applied TPM activities and downtime tracking (MTTR, MTBF) in SAP and MES using actual production data.
- Worked closely with production, engineering, and quality teams to stabilize equipment performance and improve line efficiency and OEE.
- Reviewed and stabilized spare parts systems, defining critical spares and coordinating with vendors to reduce downtime risk.
- Trained and supported maintenance engineers and technicians through hands-on, on-the-job guidance.
- Handled IATF 16949 maintenance-related requirements, including documentation, audit preparation, and corrective action follow-up
Production Engineering/Maintenance Manager
Zinus USA Inc.
07.2020 - 10.2023
- Led capital projects for new production lines and new product launches, covering equipment selection, installation, and production ramp-up.
- Drove continuous improvement of automated mattress production lines to improve equipment stability, quality, and throughput.
- Contributed to the development of the MTS system concept, defining OEE, MTTR, and MTBF metrics based on actual shop-floor requirements.
- Established maintenance activities focused on downtime reduction, including TPM, CIP, QRS, and preventive maintenance standards.
- Developed and managed CAPEX and operating budgets for engineering and maintenance departments.
- Performed manpower planning and work delegation for engineering and maintenance teams based on production demand and project priorities.
- Improved quality issues and reduced cycle time through equipment modification, process optimization, and tooling improvements.
- Reviewed new machine designs and evaluated synchronization and compatibility with existing production lines prior to installation.
- Established spare parts management processes and integrated spare parts control into SAP.
- Worked directly with equipment suppliers to develop new equipment concepts that had not previously been used at Zinus, supporting the launch of new products.
- Developed production systems capable of handling high-mix manufacturing with rapid model switching, improving responsiveness to customer demand.
- Served as project manager for facility and building modification projects, working directly with U.S.-based contractors to convert warehouse spaces into manufacturing-compliant facilities.
- Led facility modification projects to meet manufacturing and safety code requirements, coordinating construction, utilities, equipment layout, and production flow.
Production Engineer
Mando Corporation
03.2016 - 04.2020
- Reviewed product designs for new model launches and EO changes to confirm production feasibility and machining stability.
- Installed and ramped up caliper brake machining lines using CNC machines and robotic automation.
- Identified and resolved quality and equipment issues through direct analysis of machines, processes, and tooling.
- Met process capability and machine validation requirements in line with APQP during new model and new line launches.
- Handled MIP, PPAP, and 4M change activities for layout changes, new model launches, and new line installations.
- Modified existing machines to reduce cycle time and improve quality, including applying simultaneous MCT ATC and APC operations across 21 production lines.
- Designed and applied tooling layouts directly, standardizing tools and machining programs across production lines.
- Worked with the MES development team to improve MES data accuracy and usability, including OEE, MTTR, and MTBF, and addressed data loss issues from CNC and automation systems as TFT lead.
- Analyzed and improved CNC machine PMC logic to enhance machine stability and data reliability.
- Directly modified and optimized CNC programs and robot programs to support new models, EO changes, and quality improvements.
- Supported technical audits and quality issues from OEM customers including GM, Tesla, Hyundai, Kia, Chrysler, and Honda.
- Supported multiple new line installations and new model launches through on-site engineering and troubleshooting.
- Guided the quality team on CMM measurement standards and inspection control methods.
- Created repair manuals, OPLs, and PKDs to reduce MTTR and improve MTBF, and provided hands-on training to engineering, maintenance, and supervisory teams.
Production Engineer
Mando Corp.
12.2012 - 01.2016
- Led MIP and PPAP activities for new model launches, including multiple engineering order (EO) and 4M changes throughout development and mass production phases.
- Supported and executed new vehicle model launches, including premium OEM programs, ensuring stable ramp-up and production readiness.
- Performed product, jig, and fixture design reviews and implemented mechanical improvements to address quality issues and enhance process robustness.
- Achieved required process capability (Cpk) and production capability targets for new models through hands-on process tuning and tooling optimization.
- Improved tooling layouts and selected appropriate tool types to resolve quality defects and reduce cycle time.
- Created, reviewed, and updated engineering documentation, including PFD, Control Plan, Work Standards, PFMEA, and inspection check sheets.
- Directly updated and modified CNC machining programs and robot programs to support new products and engineering changes.
- Executed mechanical troubleshooting and hands-on modifications of components, jigs, fixtures, and tooling to improve reliability and manufacturability.
- Supported IATF 16949 requirements, including documentation control, corrective actions, and audit preparation, and responded to ISO 9001 audits.
Education
Bachelor's degree - Automotive mechanical engineering
Kookmin University
01.2013
Skills
- Fully Automated Serial Production Line
- Autocad, Inventor
- Robot Program
- CNC Program
- Robotic Welding
- Laser Welding
- AMR
- Microsoft Office
Accomplishments
- Successfully launched multiple new production lines and new models across automotive and consumer manufacturing environments.
- Led development of RFID-based, no-changeover production lines enabling automatic model recognition and mixed-model manufacturing.
- Improved OEE and productivity by implementing data-driven maintenance and engineering strategies based on MTTR and MTBF analysis.
- Reduced downtime through hands-on machine improvements, standardized tooling layouts, and structured TPM, CIP, and QRS activities.
- Designed MES/MTS data concepts and worked directly with system developers to eliminate data loss and improve production visibility.
- Delivered measurable cycle time and quality improvements through direct modification of CNC, robot, PLC, and vision programs.
- Established CAPEX and operating budgets using operational back data, gaining executive approval for critical investments.
- Led technical responses for OEM audits and quality issues involving GM, Tesla, Hyundai, Kia, Chrysler, and Honda.
- Built strong engineering and maintenance teams by leading hands-on training and developing repair manuals, OPLs, and PKDs.
- Secured CAPEX and operating budgets using operational back data, gaining executive approval for equipment, tooling, and spare parts investments.
Certification
Scuba diving master
Languages
Korean (Native or Bilingual)
Timeline
Maintenance Manager
Hyundai MOBIS North America Electrified Powertrain, LLC
10.2024 - 10.2025
Production Engineering/Maintenance Manager
Zinus USA Inc.
07.2020 - 10.2023
Production Engineer
Mando Corporation
03.2016 - 04.2020
Production Engineer
Mando Corp.
12.2012 - 01.2016
Bachelor's degree - Automotive mechanical engineering
Kookmin University