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Resume of QHQ
Consultant
EXPERTISE AND SERVICES
Automotive Assembly Plant Design, Feasibility Study Expert ConsultantExpertise in automotive assembly plant design and implementation, industrial engineering, lean manufacturing, confidential program planning, feasibility layouts and studies, and program facility layout development.
Highly experienced in areas including program management, timing and funding, timing charts, assembly process requirements, contract bid layouts and specifications, equipment bid packages, conveyor and related equipment design and engineering, owner and supplier coordination, program documentation management, on-site equipment installation management, start-up and de-bug, facility and equipment layout.
Additional experience and specialization includes process engineering, program budget for tools and equipment, feasibility layouts, facility cost estimates, manpower assessments, new process development and documentation, staffing model and operating plan evaluation, equipment development, delivery, installation, and manufacturing process database development.
Additional areas of expertise include thin client terminals, new process operator job instruction, cycle line layouts and studies, work flow line balancing, workstation layout and consolidation, tooling relocations, material flow analysis, build carts, conveyor redesign, field crew supervision, work load station heights, detail carrier design, robot cycle time and reach issues, ergonomic issues, and conveyor systems
PRINCIPAL INDUSTRIES SERVED
Automotive, Commercial Transportation, Manufacturing, Robotic Assembly
PROFESSIONAL EXPERIENCE
Consultant, Kevin Kennedy & Associates, Inc.
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Providing industrial engineering, automotive assembly plant design and implementation consulting, program planning, feasibility study consulting, forensic engineering and related expertise to a wide variety of clients.
Speak to this experienced, world-class expert now.
- Call (317) 735-7478
- E-mail qhq@rapid-response-consulting.com
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Project Manager, Process Engineer, Blue Bird Liberty Project, Transit School Bus, Atlanta, GA
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Brought transit style school buses from Blue Bird’s North Georgia Assembly Plant to their Fort Valley Assembly Plant. Overcame severe quality and complexity issues resulting in project time line of only 4 months, completing the project on time and on budget. Project responsibilities included organization of the engineering team to accomplish the task. Project management responsibilities included overseeing both facility and equipment layouts as well as process engineering. Developed a detailed program budget for tools and equipment. Coordinated release of bid packages to conveyor and equipment vendors. Monitored program progress by maintaining a program schedule. The project team also assisted Blue Bird in reaching a 30% reduction in manpower levels from historical levels, attained through the use of specific work instructions assigned to each operator and performing time studies to balance the work load among the operators.
Project Manager, Blue Bird Bus Company (LMB Commercial Bus) Atlanta, GA
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Developed feasibility layouts and facility cost estimates to assist Blue Bird in the merging a new commercial bus product onto an existing commercial bus assembly line. This included manpower assessments, facility cost estimates and various layout concepts, documentation of the existing process and development of a process for the new bus. The product integration includes balancing the work load on each operator as required and material and facility layouts to insure a workable process.
Project Manager, Conventional Bus Chassis, Blue Bird Bus Company, Atlanta, GA
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Developed feasibility layouts and facility cost estimates to assist Blue Bird in the decision of a location for a new conventional chassis line. This included manpower assessments, facility cost estimates and various layout concepts in three different assembly plants, and evaluation of various staffing models and operating plans. After final program direction was determined, bid documents were prepared to obtain competitive quotes for conveyor systems, bridge cranes, air tools, fixtured multi-spindle tools and process fluid fill equipment. Overall layout was maintained throughout the project to coordinate all construction activities within the selected plant. Oversight of equipment development, delivery and installation, as well as problem resolution, were among other responsibilities.
Developed the Manufacturing Process Database specifically for Blue Bird to document all process steps, materials, and tooling requirements. With the use of the database our team improved Blue Bird’s budgeted man hours per chassis from 42 to 23 through improved facilities, balancing operations and creating a layout which has sub-assemblies feeding directly to the line. The Manufacturing Process Database was completed at the launch of the first units allowing all material and tools to be located in their proper stations and in the proper assembly sequence. A unique feature to this Manufacturing Process Database was the real time connection to product illustrations on the assembly line. Through the use of thin client terminals an operator on the assembly line was able to look up his operation, read a description and if needed, through the use of a hyperlink, go directly to the specific product illustration for his job.
Project Manager, Detroit Chassis Plant/B-750 School Bus Chassis, Detroit, MI
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Project Manager for the integration of the B-750 school bus chassis into the existing facility. Management responsibilities included re-rating of the facility from 12 JPH F53 motor home chassis production to 8 JPH with a mix of motor home chassis and school bus chassis production. Industrial engineering responsibilities, based on production schedules, included development of new process operator job instructions utilizing MS Access Database, updating manpower requirements, detailed cycle line layouts, work flow line balancing to accommodate both products, tool and facilities layouts and operator job assignments based on cycle line studies.
Project Manager, Lean Manufacturing Program, Detroit Chassis Plant/Trumack Assembly Plant, F-53 Motor Home Chassis, Detroit, MI
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Was responsible for the lean manufacturing team to apply Industrial Engineering practices and identify the means and methods to manufacture existing product to increase profit. This included workstation consolidation by means of operator cycle time studies, integration of sub-assemblies to the main line where feasible, tooling relocations and material flow analysis.
Postal Vehicle Chassis, Trumack Assembly Plant, Detroit, MI
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Was responsible for the integration of the postal vehicle into the existing facility, re-rating production from 22 JPH building F53 motor home chassis to 22 JPH integration of motor home chassis and postal vehicles, and the redesign of build carts and conveyors for integrated build using existing line operators. Industrial engineering responsibilities based on production schedules included manpower requirements, detailed cycle line layouts, work flow line balancing, tools and facilities layouts and operator job assignments.
Engineer, Kentucky Truck Plant, Ford Motor Company, Louisville, KY
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On-site engineering for installation and rework to the final area for the new Crew Wagon. Working closely with Ford process engineers to design operator work station layouts and process operator job instructions, and layout facilities for a new trim department and pre-delivery area that would meet projected volumes and complexities of the new vehicle. Existing engine, frame and final build lines were integrated with the new and existing product. Engineering timing studies were performed to carefully integrate the new vehicle with the existing product to insure that no bottlenecks. Field engineering included supervision of field crews and working with sub-contractors to install new conveyors, related facilities and tooling equipment. Coordinated with tooling vendors for the installation of tools to avoid interferences with new or existing facilities and generated weekly updates of plant AutoCAD layouts for review by plant and vehicle operations personnel. Detailed timing charts were created detailing all aspects of job progress, engineering, fabrication, delivery, electrical, air piping, mechanical installation, programming, de-bug and start-up.
Engineer, Kentucky Truck Plant, Ford Motor Company, Louisville, KY
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On-site engineering for installation and rework to the pre-delivery department and final area for the new super duty, ‘F’ line. Coordinated with vehicle operations engineers and plant personnel in process development and facilities implementation. Provided weekly updates of layouts for review by plant and Vehicle Operations personnel, and detailed timing charts were created detailing all aspects of job progress; engineering, fabrication, delivery, electrical, air piping, mechanical installation, programming, de-bug and start-up. Field engineering included supervision of field crews and working with sub-contractors to install new conveyors and equipment.
Belvidere Assembly Plant, Chrysler Corporation, Belvidere, IL
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Coordinated and developed with Chrysler and suppliers the new body-side tooling and facilities. Coordination included work load station heights, detail carrier design and robot cycle time and reach issues. Conveyor layout design included two new power and free conveyors and rework to one existing conveyor. Carriers had to be designed for an integrated build of both new and existing product. Detail design for a new inverted power and free carrier to allow integrated build, using CAD files to verify pick up points. Design of the carrier was coordinated with the tooling vendors to avoid interferences with tooling stations, clamps and welders. Detailed conveyor and carrier design for new body shop tooling. Maintained coordination between tooling vendor and robots.
ADDITIONAL EXPERIENCE
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Bramalea Assembly Plant, Chrysler Corporation, Bramalea, Ontario
Phase I involved the creation of feasibility layouts and cost estimating for the body shop for the new LH models. Responsibilities included layouts of conveyors, facilities and tooling, as well as cost estimating for funding purposes. Phase II involved the approval of contractors to installation. Responsibilities included analyzing layouts for verification of system requirements, maintaining the overall body shop layout to identify potential interference’s between tooling and conveyor contractors, suggesting alternate layouts. Direct contact with Bramalea personnel in laying out process workstations, including all facility and material handling requirements. Attended weekly meetings with all tooling vendors to ensure that all hand off points between the tooling and the conveyors were satisfactory. Suggested alternate layouts for tooling to help improve process flow. Created of timing charts and timing layouts to coordinate the installation of the new facilities and tooling.
Chicago Assembly Plant, Ford Motor Company, Chicago, IL
Detailed power and free conveyor layout and design for Dearborn Midwest for the new body shop for the Taurus program. Project included coordination between the tooling vendors and conveyor contractors for load station locations, carrier design, cycle times and ergonomic issues. This coordination also included suggestions for facility/tooling arrangements to improve the layout for conveyor design and material handling.
Ontario Truck Assembly Plant, Automatic Systems Inc., St. Thomas, Ontario
Detail conveyor and system design for new paint shop conveyors
Please note that this is an abbreviated CV. A fully detailed unabridged CV is available under special circumstances.
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Kevin Kennedy & Associates, Inc.
Rapid Response Engineering® Solutions
3905 Vincennes Road, Suite 320
Indianapolis, Indiana 46268
(317) 536-7000 voice
(317) 536-7220 fax