Darrell Long

Experience

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  Delphi

  Jan 2000 - May 2007

  Senior Manufacturing Engineer / Project Manager

  I managed manufacturing engineering projects for new product launches through to final customer acceptance, meeting cycle time and tool life goals by optimizing machining processes. I developed concepts for gauging, work holding, and cutting tools as well as wrote RFQ specifications for machine purchases and prepared cost estimates. Key accomplishments included:-- Spearheaded four turnkey machining projects at multiple plants in the US, Mexico, and China, including an accelerated project with a 33% reduction in time for completion -- Slashed cost of redundant inspections and reworks by $1.5M per year by implementing a thread forming process for all master cylinder inlet processing-- Cut $100K in scrap annually by developing an innovative deep-bore reaming process that eliminated chatter by introducing changes in spindle RPM as a vehicle for vibration dampening Show less

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  ADVICS Manufacturing Ohio, Inc.

  May 2007 - Jan 2011

  Senior Manufacturing Engineer / Project Manager

  I managed full-cycle machine line installation and process retool projects in support of new product launches and plant layout changes. In addition, I developed supporting engineering drawings and documentation for all projects. Actively participated in continuous improvement processes and provided problem-solving expertise. Key accomplishments included:-- Led nine new equipment installation and retool projects on CNC-controlled horizontal and vertical machining centers, drilling machines, lathes, broaches, and special-design milling machines to support the production of cast-iron brake calipers and brackets-- Spearheaded the installation of a brand-new machining line; coordinated all operations, including machine rigging, utilities preparation and hook-up, safety operations, lathe chuck balancing, chip handing & disposal system, and overall design of the line layout-- Transformed a machining line lagging in performance into the most productive line by stabilizing the entire production process; saved $50K annually by eliminating the need for a redundant operator and cut changeover time by 12 hours per week Show less

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  BWI GROUP

  Jan 2011 - Jul 2022

  I provide direct production support to the fabrication, CNC machining, and tube forming processes as well as develop work instructions and offer training assistance. In addition, I devise and implement various process improvement initiatives to enhance quality, uptime, efficiency, and cost, and revise control plans and other process documents as needed.Key accomplishments include:-- Took control and stabilized the hot tube forming process after its functionality had declined when key operators left the department; eliminated leaky damper rejects being shipped to customers through process stabilization -- Increased uptime for the hot tube forming process by 40% and stabilized overall process quality by redesigning the forming tool -- Cut groove machining cycle time by 8%, increasing process capacity to an additional 3000 tubes per week, by optimizing the CNC program; increased the groove machining process capacity by another 1350 tubes per week by streamlining the material verification procedure -- Increased punch press uptime by 60 minutes per shift by eliminating false rejects by developing a more reliable part presence sensing system Show less I integrated machining processes for 13 new product launches, overseeing projects at three sites in the US, Mexico, and China. Developed, stabilized, and optimized CNC machining processes within tight budgetary and time demands. I also supported plant floor engineers by providing guidance and creating detailed documentation critical to process operations.Key accomplishments included:-- Served on the new Greenfield Plant’s start-up team and developed spare parts and preventative maintenance recommendations from scratch to minimize operational risks; assisted in developing a chip disposal system, the DI (de-ionized) and RO (reverse osmosis) water distribution plan, and the coolant chemical plan -- Led the installation of CNC turning processes for the production of steel piston rods for automotive dampers at the Chihuahua, Mexico plant; developed Spanish work instructions and control plans to ensure optimal interpretation -- Managed all Brakes Division machining process installations at the Shanghai, China plant; integrated CNC machining processes for aluminum automotive knuckles and cast-iron brake calipers; installed re-tooled CNC machining processes for nodular iron brake rotors on VTL lathes -- Developed companywide manufacturing standards for brake rotor and knuckle machining-- Saved $161K in downtime by implementing Shainin System (SS) to resolve the machining chip control issue Show less

  • Phase 3 Manufacturing Engineer

    May 2020 - Jul 2022

  • Senior Manufacturing Engineer / Project Manager

    Jan 2011 - May 2020
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  Gosiger Inc

  Jul 2022 - now

  Technical Project Manager