Stacy Pullins Email & Phone Number

Princeton, Indiana

Houston, Texas Area

Cameron, Texas

I was responsible for leading the cross functional Operations Staff including Production, Maintenance, Engineering, Planning, and Procurement. During this time, I redefined the Production Planner role to provide a sharper customer focus, hired two key process Managers to lead their respective teams, and refocused our Safety culture which resulted in a reduction of injuries by 50%. Under my leadership, we reimplemented the existing Quality System as a means to improve product and process performance.

Cameron, Texas

I came aboard with Butler and was given ownership of the Order Entry process. I quickly upgraded the order processing tools by implementing Autodesk Inventor to create better shop drawings. From there, I was responsible to commission a newly acquired 100,000 sq. ft. warehouse and turn it into manufacturing space. At the same time, I purchased and installed a new CNC plasma cutting machine and constructed a 10-ton overhead bridge crane to service this machine. Finally, I led the charge to implement a new ERP system for the business, developing all the processes and training all the employees.

Houston, Texas

Our Engineering Team owned all product development, development and maintenance of all manufacturing processes, and, CNC programming. The Design team revamped their processes to tighten document control methods and design procedures, ultimately contributing significantly to our ISO certification in October 2012. At the same time, two new products were rolled out; the first was a new modular cabinet for mobile military applications which provided access to new markets for the business; the second was a next generation of ISO Storage Container which met weight and cost reduction targets.Even though the process engineers were heavily involved in product development activities with the designers, they too had their own projects. A new Powder Coat Paint line was implemented, which replaced a wet paint system, and more than doubled the output of the previous system. Also, a newly acquired warehouse was prepared for future manufacturing space.

Houston, Texas

I joined Powell as a Manufacturing Engineer, recruited primarily for my welding process expertise. In my initial role, I implemented new welding processes for the Structural Steel fab group that ultimately increased their productivity by 50%.In August of 2005, I acquired responsibility for the day-to-day operations of all Fabrication teams. The group ultimately doubled in manpower and output within our first three years together as we were responsible for supplying assembly operations at multiple sites with the painted steel and copper parts they needed. With the help and support of my Supervisor, their teams, and my small group of Manufacturing Engineers, we were able to consistently satisfy customer demand, within budget. The single greatest achievement I was part of during this tenure was to lead the team in transforming our Safety Program. We started with an OSHA Incident Rate (O.I.R.) of over 6.0 in 2009, and by early 2012, managed to change the culture and work methods, which led to an O.I.R. of 1.12.

Waterloo, Iowa

My mission from day one was to develop the business case to bring robotic welding to the manufacture of tractor cab frames. After assessing the existing operations, I developed a three stage plan, ultimately resulting in a budget of $8.4 MM. After the project was funded, I led all procurement and technical activities with the support of a small, highly skilled core team. The first piece implemented involved installing two CNC laser cutting machines, one CNC press brake, and one CNC metal folding machine. This cell produced parts needed in the welding operation on a JIT basis, using visual triggers for replenishment and did so at a 15% cost reduction.The second piece was the most innovative and involved using a tube laser cutting system to process parts from stock lengths. From there, a material handling robot would unload the tube laser and either feed parts into a tube bender, or, rack tubes onto a cart. The project generated over $200k of annual savings.The crown jewel of the program was the robotic welding system. This workcenter consisted of 4 stand alone Robot cells producing sub-assemblies for the automated main line. The Main Line consisted of an overhead lift and carry conveyor, feeding 4 robot welding stations, and one manual station and the end of the line. In addition to more consistent weld quality and product dimensions, the system yielded an annual cost savings of $1.5MM.

Mesa, Arizona

SDI makes initiators for air bags and seat belt pre-tensioners. I joined them because of my welding automation and process development background. In this role, I also had the opportunity to utilize some of the skills I acquired in graduate school through the use of Statistical Process Control (SPC), Design of Experiments (DOE), and Root Cause Analysis (RCA). While there, I developed and implemented a revolutionary "closed-loop" resistance welding process for "squib" wires, ultimately improving uptime by 15% and yield by 5%. In a high-volume environment, those margins are significant. Lastly, I developed an aluminum Nd:YAG laser welding process for the company's new seat belt pre-tensioner product line. This process paved the way for SDI to enter that market.

East Moline, Illinois

As a welding engineer, I was responsible for justifying, specifying, and implementing Robotic Welding Cells. All projects were focused on labor cost reduction, and improved product quality. Over this period, I installed 7 robot welding cells, performed all weld process development and robot programming, and trained operators and shop floor engineers.

Moline, Illinois

Recruited out of Grad School to the John Deere Technical Center. I was part of a program to replace welding experience at the operating units which was soon to retire, with BS Weld Engineers. My assignment while at the Technical Center was to develop new software for Pulsed Gas Metal Arc Welding. In this capacity, I partnered with several welding equipment manufacturers to find a "welder friendly" pulse waveform that would be accepted by more traditional welders. I ultimately installed this software in several operating units and gave hands-on training to over 100 welders across multiple sites.

Master Of Science (Ms), Welding Engineering

Activities and Societies: American Welding Society

Bachelor Of Science (Bs), Welding Engineering

Activities and Societies: American Welding Society

Education record