Robert M Kachelek Email & Phone Number

Waukesha, Wi

Waukesha, Wi

Menomonee Falls, Wi

Led new and current product development validation with staff of 12 engineers, technicians, and testers. Assembled prototypes for component and machine level testing and durability evaluation. Created and coordinated project resources and risk-based machine design verification plans with product engineering. Guided effective global communications with technical and non-technical levels, executives, cross-functional teams, and suppliers.- Designed and implemented SharePoint work requests management and scheduling system for all activities in test and validation unit, allowing real-time work order status and reporting for requestors and facilitating accurate resource planning and current work-load reporting.- Linked failure mode and effects analysis (FMEA) and design verification plans, mitigating product and project risks, and leading to reduction of design and validation redo loops and decreased time to market.- Defined and instituted daily / weekly / monthly 5S program, creating more pleasant workplace, improving quality of work, reducing non value-added activity, and boosting testing efficiency and safety.- Increased capabilities by redesigning facility to accommodate test and validation of mobile hydraulicequipment, including installation of portable refrigeration, building updates / upgrades, and expansion ofoutdoor machine test facility.- Designed and implemented SharePoint-based global dashboard warranty reporting system that interfaced with Excel and reported on key product and warranty key performance indicators (KPIs), allowing users to query database of warranty claims, driving continuous product improvements.

Oversaw product liability claims involving personal injury or property damage. Partnered with external counsel and insurance company to gather and assess information. Provided answers to interrogatories, fulfilled requests for documents, gave depositions, and offered expertise to product inspections and settlement mediations.- Served as lead member of product safety committee, conducting machine hazard safety walk-arounds to assure product safety compliance and consistency between products.- Developed and implemented product recall decision tree guidelines, facilitating consistent decisions andresponses to product recalls, including actions requiring Consumer Product Safety Committee (CPSC) reporting.

Guided maintenance, facilities, and tool room / tool design departments with union and non-union workforce of 20. Ensured availability of machine tools through robust preventive maintenance program with 3-shift maintenance staff. Designed and manufactured tooling for machining, welding, fabrication, and assembly operations.- Improved internal customer response time 15% by developing and implementing online tooling and maintenance work request system.- Oversaw 100K sq. ft. manufacturing expansion, increasing plant capacity 20%.

Directed Quality Assurance department with union and non-union workforce of 10. Oversaw plant, supplier, and external customer quality for 2 US-based facilities. Presented and reviewed factory KPIs with executive management, including quality, efficiency, conversion cost, and machine up-time. Made key decisions during supplier selection and qualification process.- Implemented statistical methods for approval of manufactured and purchased components, focusing on supplying consistent quality components utilizing concepts of production part approval process (PPAP).- Decreased operating costs $500K annually through elimination of roving inspection and implementation of quality at the source.- Applied concepts of Six Sigma when instituting company-wide decision-making, leveraging power of data to drive objective, quantifiable metrics and improvements.- Implemented ISO 9001:2008 and created online, paperless, document management system for policies, procedures, forms and templates, guaranteeing up-to-date policies, procedures, and forms throughout company.- Drove down warranty rates 40% by creating and utilizing online warranty reporting system to implement actions.- Reported monthly to executive leadership on key product and warranty KPIs and status of ongoing corrective actions, enhancing communication and decision-making.- Reorganized factory layout twice and expanded facility, implementing concepts of one-piece flowmanufacturing.