Rick Thomas Email & Phone Number

Morrisville, Nc

Manufacturing Engineer Aug. – CurrentProvided front line technical support to resolve process and quality issues. Process included:• Pharma Works TF2 blister packaging• Cognex Vision system to inspect print and verify filled package• Staubli Robotics• Pick and Place Systems• Eclipse filling machines• IVEK Micro Pumps• Vibratory Feeders• ADCO packaging machines• Level 9 clean room

Kenansville< Nc

Knitting Warping Weaving Supervisor 2016-2018Supervised 30 production employees and 157 machines used in manufacturing automotive interior fabrics.• Ensured adherence to safety, quality and production standards through daily team meetings to cover issues of the past 24 hours, modify procedures and set new expectations. • Recommended and implemented process changes that improved quality and productivity.• Wrote and modified process documents, defining production methods and tasks; created management spreadsheets and reports.• Mentored 2 potential supervisors leading to their promotions.Process Engineer in Finishing Department 2014-2016Oversaw 4 tenter-frames where fabric was coated with various chemicals then processed at high temperature and tension.• Made increased sale of woven products possible by taking ownership of equipment previously installed by others but not made operational by them; learned operation, determined settings, then taught technicians and operators. Two years later, 5 additional looms were purchased for weaving department to meet increased demands.• Discovered that out-of-control fabric weights were being caused by lack of maintenance of control devices; repaired on all tenter-frames, documented theory of operation and established a maintenance program that ensured continuing performance, minimizing customer complaints and reducing internal losses.• Improved fabric drying by using manometers to know when circulation fans in an open-loop system were failing. • Found, purchased, and made automatic chemical-dosing system operational, improving fabric quality by delivering accurate amounts of chemicals at correct time.

Red Springs Nc

Charged with improving and sustaining 5-component lamination process through data analysis, problem solving techniques, design changes, documented procedures, and process auditing. Manufactured product was a diaper component. Acted as plant manager during plant manager’s 5 months absence.• Led all continuous improvement efforts, making process and quality improvements that increased plant’s yearly sales volume 65% and profits 300%.• Increased plant capacity 25% through a line speed up; extensive in-house product testing and trials at the customer proved no negative effects.• Qualified 3 alternate raw materials and qualified and commercialized 2 new products.• Increased Process Reliability from 78% to 94+% by:o Continuously making Pareto charts of downtime reasons then using 5 Why methods to determine root cause;o Challenging line settings, proving and documenting new settings, not allowing operator adjustments without statistical or other valid reasons;o Establishing weekly auditing of process settings; ando Reducing changeover time from 12 to 4 hours by making changeover kits and carts.• Lowered customer quality claims significantly, making Tredegar the preferred supplier by:o Placing all raw material webs on machine centerline so automatic adjustments were made around centerline;o Using vision system to measure dimensions and alarm operators when dimensions reached control or specification limits; ando Eliminating persistent quality problem by correlating wear of a machine component to the occurrence of that problem.• Determined erratic pneumatics behavior was caused by wet compressed air; specified and purchased higher capacity air drier, eliminating issues.