Terry (Tee) Thomas Email & Phone Number

Greeneville, Tennessee, United States

Vooner vacuum pumps and compressors are designed to reduce and maintain low long term operating costs for a wide variety of applications.

Greeneville, Tn

-OEM manufacturer of consumer goods and contract manufacturer (automotive, etc.).Sole Engineer over consumer product assembly line. Accountable for production support, equipment and efficiency improvements, safety, reducing costs, assuring product quality. • Eliminated significant safety events in first year from 1+ major (impaling hands with rivets, lacerations that required stitches, etc.) with several minor injuries (torn rotator cuffs, back injuries, etc.). Re-trained technician to set up safety devices correctly, implemented job rotations and ergonomic workstations, created daily safety check off sheet for operators, led group and one on one safety training and performed safety audits.• Scrap Reduction Project Manager (5-person cross functional team). Within 9 months, reduced scrap plantwide from $40K/month to target of <$15K/month. Addressed technical issues, created and implemented audit procedures and trained personnel. Selected results/process: - from +$15k/week to <$2k/week: systematic fixes to reduce variability in assembly machine. - used six sigma tools (pareto charts, spaghetti diagrams, etc.). - trained / re-trained operators - identify quality parts and trained operators on equipment.• Created plant floor layouts, tooling drawings (SolidWorks) and worked with tool makers. • Selected, designed, programmed, and installed new vision system (determined system specifications, drew electrical diagrams for quality checks, etc.).• Set monthly records in production from 2.8k parts/day to 4k parts/day while reducing scrap from $15k/week to <$2k/week by improving equipment robustness, efficiency improvements and training.• Wrote work instructions, PFMEA, Control Plans, designed fixtures, and equipment improvements, wrote PLC programs and developed electrical schematics.

Kingsport, Tn

• Leveraged multi-disciplined engineering experience to consult and provide value-added work on a contract basis.• Tool Design - Designed custom fixture for cutting pistons for heat treat analysis that reduced setup time and increased efficiency and accuracy of cutting. Took 3-piston cutting procedure with high variability and labor time to 9-piston cutting process reducing labor by 50%+ - Master Tool & Die

Rogersville, Tn

Tier 1 - Leading developer of all major steering technologies providing systems that enhance vehicle control, increase fuel savings and improve performance precision. - Responsible for 5-line Rack Manufacturing area each line consisting of (laser marking, centering grinding, measuring, polishing and testing machines). - Increased production on one (1) Junker machine by 15% (2,000+ parts per week) by correcting a 3-year long problem by diagnosing and correcting an Eddy Current test. - Took initiative and out of the box thinking approach and within 21 weeks, drove down scrap rate on five (5) different Rack manufacturing machines by 25% saving $99,624 per year and spearheaded working with Maintenance Manager to correct the root cause issue located in another department. - Drastically reduced several 6-year long issues (life of lines): - - #1 cause of down time on assembly machine by 75% by researching and purchasing a new load cell that lasted 4 times longer than existing load cell. - - Increased cam follower life span by 3-times and load capacity by 50% by designing a more robust solid cam follower for the final test stand, previously causing large downtime issues. - Drastically reduced the failures / scrap rate by 50% at the first station by identifying the root cause of rejects on assembly station and changed to a longer proximity sensor.Within four (4) months, increased production of the Racks manufactured on the line by 20% (avg. 5000 racks/week) through: - - Reprogramming accuracy of the Magnaflux’s Quasar machine to determine good/bad parts that freed up the operators from rerunning parts to accurately monitor and respond quickly to machine. - - Optimizing the speed of all motions of the operations (laser markings, open/shut doors, clamping of parts, etc.) of all 5 machines on 3 lines (15 machines).

Round Rock, Tx

-Temperature sensor manufacturer for nuclear, aircraft and industrial industries. • Worked as Manufacturing/Process Engineer (improved production, reduced scrap, training, directing work with operators, etc.) over the Element Department and as Project Manager over several simultaneous, plant-wide projects from $1.2M to $3M.• Reduced failures in one line by 40% by creating and implementing all SPC charting for all departments. • Yield tracking of manufacturing processes – Researched and selected low cost, easy to use SPC software. Created stand-alone spreadsheets in Excel, and trained operators for continuous improvement.• Within 2-months, learned new programming language, identified and corrected numerous software bugs that caused Winder to freeze that no one else could fix. Winder Equipment Improvements and Redesign project.• Successfully reformulated non-lead-based glaze within one year by self-study and quickly learning glazing compounding that no one could accomplish in 20 years with successful approval from customer and increase in revenues by 31% per part (~ $150K+/yr.).• Project Manager: Achieved 150% of goal for $1.5M Nuclear Temperature Application project. Accountable for all aspects (raw materials, manufacturing, testing and shipping) in getting product to nuclear reactor customers. (Ultra)• Took initiative and won company-wide Innovation Idea Contest two (2) times (only engineer to do so): Entry into New Market with current product and New Product Design with quality improvement idea with 40% cost reduction.

San Antonio, Texas Area

-Took initiative and eliminated on-going quality issue with wiring print. Identified, sourced and installed ink curing UV light system that equipment manufacturer said “could not be done.”-Quickly learned equipment, identified and repaired resistance welders that no one else was able to repair.

Independence, Mo

ATK Contractor operating Lake City Army Ammunition Plant (LCAAP) - largest manufacturer of military ammunition and integrated medium-caliber gun systems.- Within 3 weeks of starting work, saved $600K/month by fixing 2-month long vision system problem.- Wrote government proposal-Broad Agency Announcement that brought $1.2M new government business. - Took initiative and saved time (4 hrs vs. 48 hrs) in FEA stress analysis of metal components- found customized metal forming FEA analysis software.- One of two person team to achieve ISO9001 certification for the R&D department-wrote quality procedures for Engineering Stage Gate Lean Enterprise System.Project Manager (Technical Lead) - Project: 0.50 cal Core Feeding- Led cross-functional team of engineers, delegated tasks, established timelines and followed through to assure completion.- Within 4 months after taking over project, drove project to 60% completion (previously stalled for 2 years at 10% completion). Drove project to completion through building a consensus among the team, realigning the team members’ expertise, and facilitated the completion of the working prototype. .- Led review meetings to executive board and managers. Project Manager (Technical Lead) - Project: Cold Heading Green (lead free) Penetrator - Drove team, took initiative to define areas of technical issues and worked closely with manufacturing in process changes that resulted in an accurate end-product.- Wrote statement of work for work required and expected deliverables by suppliers. - Worked with Purchasing and Supply Chain Manager - led meetings with suppliers and established goals and action items. - Ensured successful prototype sample lot of full geometric compliance. - Developed customized alloy optimized for performance and manufacturability. Test Coordinator: Lead Free Ammo Project- Wrote test work instructions, scheduled and monitored testing, analyzed data and wrote accurate and easy to read formal reports.

Johnson City, Tennessee Area

Tier 2 Automotive supplier: Premier company for automotive lubrication and fluid handling systems world-wide.Sr. R&D Engineer (3/01 to 11/2007)-- Worked with Program Manager and customers on new product launches.-- Project responsibilities from design (DFM/DFA), budgeting, prototyping, PFMEA/DFMEA, testing through working with manufacturing to ensure new products or product redesigns were easily manufactured (PFMEA/DFMEA).-- Interacted with customers on daily basis to answer questions and provide product support.-- Reduced labor cost by $350K a year and decreased downtime by 90% through redesign of mechanical components to extend component lifetime. -- Along with with Boeing and SAE Aerospace, wrote the industry regulatory standards on aircraft grease fittings.-- Reduced costs: $125K by eliminating unnecessary parts and making material changes; eliminated $100K by replacing parts washer with oil bath. $180K by removing unnecessary components to hydraulic pump assembly.-- Reduced lead time by 80% by replacing component materials for hydraulic pump.-- Resolved on-going 'large customer' issue by redesigning non-drip nozzle with customer feedback of “one thing that was well redesigned” and “met our needs.” -- Designed new products and re-designed existing products for quality improvement and/or to meet custom needs. (relief valve for battery powered grease gun, new zerk fitting, hydraulic track tensioning fitting improvements, etc.).

Johnson City, Tennessee Area

-- Within nine months of starting work, redesigned existing $3M machining operation operating at 35% efficiency for 3 years to consistently operating 85%+ (avg.) and 98% peak efficiency. Company dropped lawsuit against equipment manufacturer and placed order for 2 additional machines implementing redesigns. -- Machine design and construction responsibilities including: mechanical, electrical, controls, automation, tooling, fixtures, gages, etc. for production lines.-- Project responsibilities in working with design engineering for DFM/DFA compliance review for new products.-- Worked with design engineering to bring new products through manufacturing including, capital specifications, tooling & gage specifications, production trials and PFMEAs.-- Developed new manufacturing processes (layout, sequence, equipment, tooling, documentation).Forecasted long term planning for manufacturing and capital requirements (capacity, cycle time analyses, etc.).-- Developed capital equipment recommendations and managed capital projects.ISO9001/ TS16949 experienced. Internal auditor to help company transition into TS16949 certification.-- Reduced labor cost by $350,000 a year and decreased downtime by 90% through redesign of mechanical components to extend component lifetime. -- Designed numerous computer-testing systems - electrical schematics and programming of data acquisition systems.-- Designed automated vent fitting test system, which reduced set up times by one hour and eliminated technician.-- Spearheaded Vision System Assembly Machine Improvement Project (on-time and 6% under budget). Programmed system, designed lighting and camera systems, designed a vacuum test system and a method to keep production parts from leaking grease. Received praise from customers, corporate management and quality department.

Wilmington, North Carolina Area

Automotive and marine manufacturer of intake manifold runner control, OEM automotive governors and IMRC with ~200 employees.- Process engineer for intake manifold runner control, design improvements to OEM automotive governors and IMRC.- QS900 internal auditor, wrote process FMEAs and process instructions.- Taught ergonomic (Human Factors Engineering) classes.

Smithvillle, Tn

Washing machine and dryer timers manufacturing company with ~500 employees.- Electrical motor manufacturing engineer.- Responsible for bringing one million-dollar switch automation machine online.- Developed 250,000K automated parts washer.- Directed work for 15 operators.- Improved process from 60% to 80% while decreasing scrap by 70% through fixture redesigns and streamlining workflow.

- Head engineer (Manufacturing / Process & Quality) for industrial controls department. Engineer for throttle position sensors. - Wrote FMEA’s, process instructions, corrective action 8d's.- Designed and programmed automated computer test equipment and data acquisition systems.

Bs, Mechanical & Aerospace Engineering

Obtained EIT.

Mba, Business

Ms Mechanical Engineering Classes

Robotics Courses

Bachelor'S Degree, Mechanical Engineering

BS Mechanical and Aerospace Engineering degree

Master Of Business Administration - Mba