James Phelps Email & Phone Number

Bluffton, In, Us

Jim has just completed a robot automation project for a cell producing automotive A/C compressor hollow pistons. This robot cell loads machines and gages using vision technology to orient the component, measure lengths and diameters, and sort non-conforming parts.

 Oversee process development including tooling for roll marking, CNC roll forming, orbit forming, drilling, and turning.  Manage process improvement of 30,000 sq. ft. manufacturing facility; write process and work instructions. Maximize cells for process improvements, product flow improvement and creation of additional manufacturing space. Source and purchase capital equipment. Manage tool and fixture design: work holding for dial machines and lathes, induction heating and… Show more  Oversee process development including tooling for roll marking, CNC roll forming, orbit forming, drilling, and turning.  Manage process improvement of 30,000 sq. ft. manufacturing facility; write process and work instructions. Maximize cells for process improvements, product flow improvement and creation of additional manufacturing space. Source and purchase capital equipment. Manage tool and fixture design: work holding for dial machines and lathes, induction heating and dial machines. Participate in change to newer technology.Select Accomplishments: Managed process development and launch program of capital project to form fittings using CNC forming machine: achieved successful run-off of new plumbing fitting line being introduced U.S. market.  Developed fully automated robotics cell for manufacturing hollow compressor pistons ($2.3M project). Reduced manpower from 3-person/per shift to 1, while improving quality, increasing productivity 15% and allowing traceability of parts. Adapted low cost new technology in developing semi-automatic roll mark process for marking plumbing fittings utilizing existing equipment, increasing capability from 500/pieces per hour to 3000.  Developed process to offload portion of forming from CNC machine to semi-automatic hydraulic machine increasing speed from 180 to 360/per hour, increasing capacity 25%.  Increased performance of dial machines through tooling redesign, fixture design improvements, and PLC programming changes to bring machines from 290-pieces/per hour to goal of 400. Show less

ADVANCED PROCESS ENGINEER (1996 – 2002) Team with program and sales managers to quote new business opportunities and estimate ROI; quote automotive components. Work with automotive companies to reduce component costs, i.e. transmission internal components/housings and steering/wheel end components and participate in global cost reduction team. Partner closely with automotive engineers to troubleshoot and resolve design/manufacturability issues; develop/quote manufacturing… Show more ADVANCED PROCESS ENGINEER (1996 – 2002) Team with program and sales managers to quote new business opportunities and estimate ROI; quote automotive components. Work with automotive companies to reduce component costs, i.e. transmission internal components/housings and steering/wheel end components and participate in global cost reduction team. Partner closely with automotive engineers to troubleshoot and resolve design/manufacturability issues; develop/quote manufacturing processes; research best methods, interview machine builders, and determine cost estimates. Select Accomplishments: Member of cross-functional team with Ford to develop machining process for new high performance steering platform. Achieved company’s 1st design and build program dealing in concurrent engineering with FMCO.  Partnered with Daimler/Chrysler launch team to reduce manufacturing costs for proposed 6X transmission, involving several trips to Germany to review proposed processes to manufacture transmission components.  Worked with Ford to design process for new transmission hub to be machined in same cell as currently manufactured hub, modifying current CNC process to achieve desired whole positions without creating stress fractures. Team member in quoting/capturing transmission-housing program from Chrysler to replace current antiquated housing.  Implemented Six-Sigma format as key member of crisis team to revived failed launch at Farmington Hills facility; team successful at meeting timelines, quality and quantity goals of start-up. Show less

 Participate in Capital Equipment purchasing; involved statement of work, obtaining quotes, writing appropriation/P.O., machine run-off, APQP, PPAP, training, and manage operators and production start-up. Research best methods to determine cost estimates per each process; implement best process; work with skilled trades to analyze problems and find solutions, i.e. PLC, CNC Machine and Powerway issues.Select Accomplishments: Developed process prints using AutoCAD 12 for all… Show more  Participate in Capital Equipment purchasing; involved statement of work, obtaining quotes, writing appropriation/P.O., machine run-off, APQP, PPAP, training, and manage operators and production start-up. Research best methods to determine cost estimates per each process; implement best process; work with skilled trades to analyze problems and find solutions, i.e. PLC, CNC Machine and Powerway issues.Select Accomplishments: Developed process prints using AutoCAD 12 for all products across line; initiated company’s 1st paperless system.  Worked with Powerway to design system for complete data collection and data storage. Developed procedure for measuring and grinding the tapered reamers used in process, increasing tool life on reamers from 150 pieces/per sharpening to 500. Switched process from using oil based coolant to water based, eliminating need to wash oil off pitman arm before continuing through process, resulting in better flow leading to additional capacity. Introduced Micro alloy forging to eliminate heat treat prior to processing; conversion saved $1.10/per piece.  Used 6-Sigma process to develop DOE and determine root cause of rare material failure, successfully identifying product, and quarantined; recall implemented immediately. Show less