Tim Rohrbach
Wake County, North Carolina
Overview
Work Experience
Manufacturing Engineer
2014 - 2016
Completed analysis of current-state manufacturing process of tractor to create a lean manufacturing process to reduce labor, eliminate safety issues, and improve quality. • Developed new assembly methods. Calculated the reduction in labor and completed a line balance with new manpower allocations. • Develop Scope-of -Work Statement, Schedule, $800,000 Budget, AutoCAD Layouts, and RFQ/RFP for construction and purchase of M & E. • Develop/present project plan to stakeholders. Communicate with stakeholders to facilitate smooth implementation of project. Interface with accounting to verify overall project had sufficient ROI. • Lead pre-construction meetings with Plant Engineering to communicate features of new machinery so that PM programs can be updated and manuals/spare parts can be acquired prior to startup. Incorporate new equipment into TPM procedures. • Complete program risk assessment. • Create 3D virtual models and animations of new areas. • Enlist stakeholders from other functional groups such as Operations, Logistics, EHS, Plant Engineering, Security, etc. Coordinate team’s activities to keep project on schedule and in budget. • Create a lean manufacturing process to arrange the most efficient process, to identify tasks that were non-value added, and as a component of overall TQM initiatives. Improved process allowed a 15% improvement in capacity with no additional manpower. • Manage contractors as site construction and procurement of all M & E proceeds. Determine acceptance criteria for commissioning equipment prior to turning it over to Operations groups. Provide training, technical support and PLC programming of AGV and Conveyors after start-up. • Update factory AutoCAD layout upon completion. Turn over new equipment as-built drawings to Plant Engineering and Maintenance Department. • Manage Continuous Improvement Team. Supervise team of technicians that built custom tools fixtures • Deploy an AGV that reduced $110,000 in annual expense.
Caterpillar has been making sustainable progress possible and driving positive change on every continent.
Raised $5,187,349.00 from US Department of Energy, Advanced Propulsion Centre UK and NYSERDA.
Product Support
2009 - 2014
• Support introduction of new vehicles or parts by collaborating with cross-functional work teams composed of Engineering, Parts Marketing/Pricing, Publications, and global Sales Branches to verify correct service parts, in sufficient quantities at the proper price point are in place prior to introduction. • Coordinate activities of the Corporate Publications authors to assure new vehicles, products or features are covered in parts catalogs, owner manuals, and service & repair manuals. My contributions could include creating illustrations, writing content, proofreading, validating parts replacements methods and creating diagnostic procedures, etc. • Identify and champion new product opportunities such as service kits, super duty replacement parts, aftermarket components, etc. • Statistical analysis of all warranty data to determine what failures occurred in the field and the frequency of those failures using SAS MDAW software. • Create, prioritize and lead projects for Operations and Design Engineering groups to identify root cause and resolve field failures using Six Sigma 8D methodology. My projects resulted in 20% reduction in warranty costs for the products I supported. • Scheduling, coordinating, and leading monthly meetings with sales branches around the world to identify additional quality issues, and to communicate status of ongoing field resolution projects. • Visit customers and dealers in the field globally to review product non-conformances and failures. Act as a technical reference when required. • Review technical literature and dealer and customer training to ensure customers were being trained to use products safely and efficiently. • Communicate to product designers and quality teams how customers defined quality. • Review product designs to improve serviceability and to simplify repairs when field failures did occur.
Manufacturing Engineer
2005 - 2009
• Developed and implemented new assembly line for existing 900 part mowing machine that improved productivity 10% and decreased warranty costs 50%. • Developed and implemented new assembly line for golf course mowing machine that improved efficiency 12% and decreased warranty cost 30%. Recognized by corporate leadership with “Business Turn-Around” award. • Deere Production System Lane Champion for “Enabling Manufacturing Technology and Processes” that went from 76% conformance to 96% in one year. This portion included MES and virtual manufacturing systems. Project allowed facility to become DPS gold; one of only four John Deere facilities in US to achieve this status. • Furnish training and all resources to support very robust 5S program. • Led SMART tool initiative on various assembly lines to capture, store and analyze critical torque data. • Led team of NCSU Graduate students in development and implementation of MES (Manufacturing Execution Systems) Software communicated daily build schedule and illustrated work instructions to assemblers as well as the status of safety and quality metrics. Component serial numbers and date codes were absorbed as was all torque tool data. Each machine had a detailed record of all components and fasteners torque. System also served as a real time dashboard for factory leadership team. Estimated 20-25% increase in factory productivity and product quality. • Carried out Logistics Planning using Factory FLOW analysis of new assembly lines. • Train assemblers to construct new machines • Write all work instructions for assemblers. • Determine global standard assembly times to allocate labor and determine direct labor costs for products. • Lead initiative to model factory in 3D using FactoryCAD and AutoCAD • Procure miscellaneous equipment such as cranes, hoists, DC electric and air pulse torque tools, test equipment, hydraulic lifts, etc. • Designed and procured numerous pieces of tooling, fixtures, and lifting tackle
John Deere Kernersville specializes in fields including manufacturing, engineering, supply chain management, welding, and human resources.
Manufacturing and Systems Engineer
2003 - 2005
• Analyze designs of small all-wheel drive tractor and make recommendations to improve ease of assembly. • Develop global standards for labor time to assemble machine and make estimated for direct labor costs of various models. • Supervisor endurance testing for tractors in endurance areas and test tracks. Supervise fleet of machines, Operators, and mechanics that supported testing. • Managed construction of prototypes. Ordered material, supervised mechanics, prepared project plans, support designer engineers
Operations Supervisor
2001 - 2002
• Managed assembly line teams of 10 to 40 assemblers, planners and support people. • Provided leadership, through coaching, motivation, enforcement of policies, and development of personnel. • Supervised shipping department.
Operations Planner
1993 - 2001
• Developed and documented manufacturing process for assembling new compact loader from approximately 1200 parts. • Design assembly line for loader. • Research environmental factors, define requirements and write specifications for tank farm and wastewater treatment plant. • Collaborated with Architectural and Engineering firms to construct factory. • Acted as Project Manager for several large scale equipment projects. • Developed highly efficient method for assembling hydraulic systems as unit on fixtures as compared to installing tubes and hoses individually in machine. • Developed method for conveying tractor implements with frame on “tow-behind carrier” to dramatically improve material movement costs. • Developed new methods for mass-flow leak testing complex hydraulic systems that helped assure new product was most reliable new Caterpillar product introduction. • Trained assembly line personnel in manufacturing processes. • Created a small core team of “super-technicians” and trained them in diagnostics and repair of Diesel engines, mechanical and hydrostatic drives, hydraulic systems and vehicle electrical systems and welding and repairs of frames and structures. • Designed and procured numerous pieces of tooling, fixtures, and lifting tackle
Caterpillar has been making sustainable progress possible and driving positive change on every continent.
Raised $5,187,349.00 from US Department of Energy, Advanced Propulsion Centre UK and NYSERDA.