Doug Downing Email & Phone Number

Rockford, Il, Us

Though new to EWIKON Molding Technologies, I have over 25 years of experience in the injection molding industry. I have worked as a field service engineer for Toyo IMM, been RJG Master Molder III certified, worked closely with tooling, project and process engineers, and spent several years in operations management. With an understanding of how crucial the design, build and delivery of a hot runner system can be to your profitability. My knowledge of tooling and the process from the plastics point of view makes us a very valuable partner.

Responsible for the daily operations of the Molding, Maintenance and Assembly departments, while supervising up to 4+ direct reports and up to 60+ indirect reports. Through hands on training, troubleshooting, process development, process documentation and proven management skills, downtime, efficiencies and quality were improved. Implementation of PM and inventory systems in the Maintenance department (including facilities and grounds), led to a more organized and cost effective systems. By training and developing scientific and decoupled molding strategies in the Molding Department, part quality and efficiencies were positively effected. By documenting the changeover process and improving the PM plan in the Assembly department, changeovers were reduced by more than 75% and machine efficiencies were improved.Responsible from concept to validation of multiple medical inspection fixtures, including HMI and PLC programing. As well as setting up and programing vision sensors and systems.

Responsible for the daily operations of a mid sized custom injection molder, managing up to 6+ direct reports and 40+ indirect reports on a daily basis. Including but not limited to, training, process improment, maintenance, servo robot programing, capital equipment purchases, 5S implementation, management and automation.Processes were streamlined, documented and improved to ensure product quality and customer satisfaction. By implementing the early stages of 5S, shop floor clutter was removed, work steps reduced and much needed floor space was utilized for production needs to improve process flow and reduce repeated product handling steps.

Bartlett, Us

Responsible for daily operations including 24/7 operation with 60-100 employeesReduced scrap from over 5% to less than 1%Implemented LEAN manufacturing techniquesDeveloped and implemented 5S systems and trainingImproved employee morale through employee training and rewards programImproved process control and process repeatabilityImplemented RJG on several machines and jobImplemented automated part containment and separationLead design and tooling reviews to ensure achievement of congruent engineering goalsImproved sampling techniques to develop best in class long term part repeatabilityDesign of EOAT and automaton cellsOversee custom machine builds off-site to ensure project and company successWork closely with project engineers supporting all technical aspects of programsWork with tooling vendors to maintain on time delivery and to ensure robust and quality tooling on every program

Responsible for daily operations including 24/7 operation with 20-50 employeesIncreased sales from less than $200K to over $2 million in less than 3 yearsReduced scrap from over 15% to less than 2%Implemented LEAN manufacturing techniquesDeveloped and maintained a positive cost structureImproved process control and process repeatabilityCreated new projects with outside tooling vendors Maintained ISO compliancePerformed CNC and thermoforming programmingResponsible for all P/L decisions and maintaining a positive bottom line

Responsible for daily operations including 24/7 operation with 80-100 employeesConducted Six Sigma trainingPerformed time studies to achieve cost savings by streamlining processesWorked closely with Motorola and Six Sigma improvement teams to implement quality standardsImplemented LEAN manufacturing techniquesImproved process control and process repeatabilityGuided sales, quality, tooling and engineering to obtain company goals

Implemented cavity pressure to reduce scrap and abnormal variation in the processesDeveloped knowledge skills assessment test for employeesReduce scrap on in mold decorating processes by ensuring part and process repeatabilitySet-up in-house training and certification processSupervised 60-80 employeesSet-up and maintained a medical molding cell using cavity psi control and monitoring to ensure true zero defect

Performed automation set-up, training, troubleshooting and repairProvided technical sales support Responsible for training, certification and consulting services

Developed machine training programCertified process personnel in cavity pressure control and monitoring techniquesImplemented hardware solutions to support automated part containmentUtilize DOE software and techniques in conjunction with cavity pressure information to reduce time to release of new products

Responsible for in-house setup and machine trainingPerformed hydraulic/electric and electronic troubleshooting and repair