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🔧 Process Optimizer | Expert Troubleshooter | Problem Solver | Machine Design EnthusiastWith a robust background in electromechanical production equipment ranging from commercial flooring manufacturing, weld cells optimization, machining, fixturing, and tooling, I excel in troubleshooting and optimizing machinery by bridging theoretical knowledge with practical application. My hands-on approach ensures I'm on the production floor—interacting with technicians to solve downtime, working with production associates to deliver best practices, and driving process improvements directly to the equipment. I have nearly a decade in the manufacturing industry and while I have a lot of experience, I am always looking to learn and grow. Each role has had unique challenges and team dynamics. I work hard to find my niche and fill the gaps. I'm dedicated to help the team in any way I can, which has allowed me to wear many hats in the manufacturing industry. I've applied practical solutions using my education in Industrial Engineering by applying lean/six sigma methodologies to reduce waste and increase efficiencies. I have a passion for Mechanical Engieering where I apply my knowledge of electromechanical systems to come up with new or improved design solutions using SolidWorks, Inventor, and/or Fusion360. I thrive in dynamic environments and look forward for the unique challenges each day brings.
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Manufacturing EngineerKenda Tires Dec 2024 - PresentYuan-Lin, Tw -
Sr. Process EngineerShaw Industries Nov 2021 - Oct 2024Dalton, Ga, UsTechnical Lead for Process and DepartmentKey contributor in decreasing processing costs, core costs, and off quality that lead department to $2M savings in operating costs in 2023, on track for $1M improvement 2024o Drove 70% production improvement on Cutting Line over 1 year, maintained through 2024, while maintaining off quality percentage to be under goalAided in new equipment production launch $7M in assetso Lead sourcing efforts to local vendors for decreased costs and lead timeso Worked with OEM during run-offs to ensure line capability met project scopeo Project Lead and Sponsor for additional $250k capital to further improve productionLead Energy & Reliability system for process by generating targeted work orders focused on key downtime and productivity metrics. Optimized PM schedule and expanded instructionso Reduced cutting line downtime from 23% to 7% over 2 years from initiativesOwnership of Process Improvement initiatives and Operator lead roundtable feedbacko Lead Equipment Improvement Teams to put focused improvement on key bottleneck areas and simplify operation. Reduced complexity in operating equipment by championing improvements derived from Operator feedbackProcess owner of Brady LOTO procedures and EHS Compliance action items Document existing process parameters develop new ones for trial/new product offeringsPrepare charts and pull data for departmental key metrics relating to productivity, costs, quality, and safetyo Presented project updates, process improvement initiatives, and safety improvements to senior leadershipDevelop / Mentor / Train Junior Engineers and Maintenance Technicians by developing key skills needed to be successful in industry -
Process Engineer IiiMohawk Industries Dec 2019 - Oct 2021Calhoun, Georgia, UsTechnical Lead for Finishing ProcessOverseen improvements related to LVT production in finishing departmentPad attach line expert "go-to"o Took ownership as technical lead to reduce downtime, off quality, and operating costso Implemented glue weight reduction $500k/year savings with no drop in qualityo Created preventative maintenance schedule for wearable parts, sourced local vendors for roll recoating spare parts, and organization to reduce time-to-repairIn charge of servicing and maintaining dies for productiono Tracked die usage, scheduled repairs/rebuilds around production and customer needs to reduce loss in productivity due to out of service dieso Implemented CAPEX project on die storage system for finishing department to reduce footprint Reverse engineer overseas parts to reduce lead times and source locallyo Created 3D and 2D CAD drawing complete packageso Maintained great customer relations with local machine shops to ensure timely delivery, competitive pricing, and quality partsCreate improvement projects based on SAP reporting data from productionProduct development lead person when conducting trials for machine capabilityo Created capability studies and new product feasibility analysisWork with suppliers to improve incoming materialo Created channels from outside and internal suppliers to reduce quality variation and real time feedback on changes -
Process EngineerConstellium Jan 2019 - Dec 2019Paris, FrLead Process Engineer for new program and equipment launch for Body-In-White Tier 1 Manufacturing- Improve machine OEE and provide support directly to manufacturing line- Assist maintenance with troubleshooting down to root cause with short and long term solutions- Drive process improvement projects derived from machine operators- Work with Quality Department to correct part defects and solve customer complaints- Write\update work instructions, SOP’s, Brady LOTO, ECR’s, MOC’s for machines- Update PFMEA's, control plans, and process flows as the process changes and improves- Update machine CAD data as changes are made and come up with custom solutions to fixture- Design and implement ECN for customer, including complete tooling change- Lead 8D problem solving events that resulted in permanent corrective actions- Maintain Plant Layout using AutoCAD, come up with prototype layout solutions- Provided Engineering support during two program launches directly for OEM group- Work with machine integrators to setup PM list and perishable BOM's- Mentor Intern from Bartow County College and Career Academy- Provide technical support to contractors and large projects -
Process Engineer InternConstellium Aug 2017 - Jan 2019Paris, Fr- Worked as a part time intern during two program launches- Lead plant layout planning for equipment launch- Gained hands on experience working with floor employees and contractors -
Industrial Engineer Co-OpShaw Industries Jan 2016 - Aug 2017Dalton, Ga, UsLead transition to paperless production reporting using internal systems and operator HMI’s- Trained associates on best practices that lead to management action items- Supported third party vendors in new automated creeling diagram systems- Active member of Process Improvement team- Member of ISO:9001 2015 transition team- Merged Dyelots to reduce old inventory, prevent over production, and save company money- Initiated continuous line business case and capital projects
Nicholas Hensley Skills
Nicholas Hensley Education Details
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Kennesaw State University - Southern Polytechnic College Of Engineering And Engineering TechnologyIndustrial Engineering Technology -
Southern Polytechnic State UniversityIndustrial Engineering Technology
Frequently Asked Questions about Nicholas Hensley
What company does Nicholas Hensley work for?
Nicholas Hensley works for Kenda Tires
What is Nicholas Hensley's role at the current company?
Nicholas Hensley's current role is Manufacturing Engineer at Kenda Tires.
What is Nicholas Hensley's email address?
Nicholas Hensley's email address is ni****@****ind.com
What is Nicholas Hensley's direct phone number?
Nicholas Hensley's direct phone number is +140451*****
What schools did Nicholas Hensley attend?
Nicholas Hensley attended Kennesaw State University - Southern Polytechnic College Of Engineering And Engineering Technology, Southern Polytechnic State University.
What are some of Nicholas Hensley's interests?
Nicholas Hensley has interest in Science And Technology, Animal Welfare.
What skills is Nicholas Hensley known for?
Nicholas Hensley has skills like Lean Manufacturing, Microsoft Word, Construction, Maintenance And Repair, Carpentry, Drywall, Masonry, Cement, Powerpoint, Data Analysis, Ergonomics, Microsoft Excel.
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