Patrick Kearney Email & Phone Number

Dayton, Ohio Area

Launched a $100 million dollar annual sales new start-up compressor factory in Juarez, Mexico working as part of a small team of hand-picked people from previous facility. Mentored, supervised and worked side by side with the newly hired manufacturing engineers, technicians, team leaders and operators.Wrote new product cnc programs and ordered needed fixturing, tools, and gages for new product launches. Managed all new machining projects such as the flawless launch of new csp compressor.Increased daily production of the plant manufacturing constraint from 20,000 to 27,000 pistons/day through programming, fixturing, machine uptime and gaging improvements. Eliminated 10% manufacturing scrap and 100% inspection on sp/csp pulleys through tooling improvements and implementation of pre-control charting. Authored process control plans and helped to demonstrate how to apply quality control tools to prevent passing defects. The Juarez plant has not experienced any quality spills.

Identified and implemented process improvements to increase average daily cvc piston production from 24,000/day to 30,000/day without any investment. Requested and was given approval for special assignment to improve cycle times of all cnc machines in the plant, resulting in 5-15% cycle time improvements. Co-authored a report with Delphi Research Labs.

Led team of 15-20 mechanical and electrical engineers responsible for all aspects of plant machining operations.Handled performance reviews, procurement/termination of contract engineers, overtime and vacation planning, budgeting, and approval; coop and intern assignments, merit increase and promotion recommendations.

Quoted, purchased, qualified in Japan, and production launched in Ohio 30 new cnc machines with a $7 million dollar capital budget. This increased plant machining capacity by 50%.

Managed a team of 20-25 mechanical, electrical, industrial, and product-liaison engineers responsible for daily support of h6 compressor machining and assembly operations. ($200 million dollar annual sales).

Initiated and led numerous operator teams to engage the work force to improve manufacturing competitiveness in axial plate operations. The end result was dramatic improvements in productivity such that the axial plate was no longer a production constraint to compressor manufacturing.

Implemented 3 million dollar project to provide additional machining capacity to h6 cylinder line, doubling output to 20,000 cylinders/day.Identified need, made business case, specified, purchased and implemented with only $100,000 in total investment, an upgrade to plant impregnation process. This upgrade largely contributed to millions of dollars in reduced compressor warranty returns.Selected for a special assignment working with consultants to implement lean manufacturing which culminated in a presentation to the CEO of Delphi.

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