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Sofia  Packard

309 Haddington

Bloomfield Twp, MI 48304

Cell (248) 229-9876

sofia.packard@comcast.net

                                    _________________________________________________________

Objective:      To obtain an opportunity to utilize my many years of experience related to lean manufacturing, industrial engineering and process design in a greenfield or brownfield manufacturing development.               

Experience:

10/2010-Present   Applied Manufacturing Inc, Orion, MI

     Project Engineer-General Industries

·         Responsible for Tooling and Robotic Simulation for GM-A1SL program at Lansing Grand River. Process and weld path initiation, Collision Checking and Throughput analysis created and Final Deliverables to plant for robot programming. Process creation, proveout and System Layout design and delivery for Corning SDO for integration of new tooling at Erwin NY plant. Discrete Event simulation for bottle neck identification and process lean-out for particulate filter production.

11/2009-9/2010   Extreme Automation (Contracted to General Motors-WTC, Grand Blanc, MI)

     BIW DFE/Installation Engineer G1JC/G1SC/D1SB

·         Responsible for design, integration, installation and debug of G1JC/G1SC/D1SB bodyshop tooling going into Orion Assembly. Includes SOR creation, distribution, receiving and award of contracts. Project managed design sourcing, build sources and installation sourcing from pre-prototype thru SOP. Direct oversight included Underbody AGC delivery, Closure line for total contract of $3.4 million. AGC (Automatic Guided Carts) subject matter expert (SME) for a new GM standard for subassembly delivery in bodyshops. Containerization Liaison for Weld Tool Center, buyoff of prototype rack and in-process rack designs, along with virtual simulations of operator interaction utilizing FactoryCad, FactoryFlow, E-Vis and Vis Mockup .

1/2009-5/2009    Ranal Inc. (formerly DBA Koltanbar Engineering), Auburn Hills MI

     Senior BIW Process Engineer

·         Responsible for Man/Machine-Robot timing for BMW F25 project (Side Frame Inner Assembly, Side Frame Middle Assembly, Side Frame Outer Assembly, Inner Framing/Respot, Middle Framing/ Respot, Outer Framing/Respot. Utilized AutoCad, Catia V5, BMW Proprietary Systems, best practices in process design and timing in lean manufacturing layouts.

8/2008-1/2009       Geometric - Americas , Auburn Hills MI

       Industrial Engineer- ReRate Project (Pontiac Assembly Center GM Onsite)

·         Reduced line rate at Pontiac Assembly from 54.2 to 24.1 jobs per hour. Complete line balance all of General Assy (Box, Door, Cab Trim, Engine, Chassis, Final, Paint, Body in White).

·         Reworked Engine Line, reducing headcount from 25 to 11, combining or eliminating jobs and reducing line speed.

·         Utilized Standard Work Authoring Tools (SWAT) to reduce headcount by 60%.

·         Project scope was $1.4 million for tool relocation, new tool purchase and labor with a forecasted savings of $8.2 million annually.

2/2008-8/2008        Ranal Inc. (formerly DBA Koltanbar Engineering), Auburn Hills MI

       Senior BIW Process/Design Engineer

·         Trained layout group in Bangalore, India in system layout guidelines, FactoryCad, FactoryFlow, best practices in process design as it relates to lean manufacturing layouts.

·         Established off-shore utilization for GM programs included crossover vehicle for a new Mexico plant. Provided plant deliverables on time and within budgetary constraints.

·         Training involved cleanup of tools in UG, exporting tools utilizing FactoryCad, systemic problem solving for file size issues and work-around, overall facility design, 8-sheet format use and creation of a reuse library for FactoryCad items that are generated.

8/2007-2/2008         Integrity Staffing Group , Farmington Hills MI

        Project Engineer- Unit Handling (Jervis Webb onsite)

·         Created and implemented 3D Baggage handling conveyor object library for Webb. Established the library and trained 2-D designers to use 3-D. AutoCAD and Inventor both utilized to create and distribute library to end users. 3D estimated to save 25-30% on estimated design hour requirements on future programs through enhanced interference checking earlier in the project.

·         Designed baggage handling conveyor systems for the Port of Portland Airport ($8.2 million). Responsible for layout and coordination with other disciplines (i.e. HVAC, plumbing, electrical and architectural etc.), and for layout of all support steel and seismic bracing.

2/2007-8/2007     Applied Manufacturing Technologies, Orion MI

     Senior BIW Process/Design Engineer (GMDI)

·         Designed system layouts and tooling layouts for Pick-Up Box lines at GMT900 plants in Flint, Pontiac-East, Ft. Wayne, and Oshawa-Truck. Oversaw creation and design of system layouts and tooling layouts for GMX521 and GMT561 Front Motor Compartment lines at Oshawa-Car and Spring Hill.

·         Customer interaction with GM customers to establish project scope, deliverables and sign offs.  Work was in 3D Factory Cad, and involved correlating activities with the various design groups, UG tool design, Delmia robot simulations and GM. Project scope was $7.8 million in tooling and labor.

 

3/2003-2/2007      Koltanbar Engineering (now DBA Ranal Inc), Troy MI          

     Project Lead- (3D Deployment Team GM Tech Center)

     Senior BIW Layout/Process Lead- (GMT966 Program)

·         Created and maintained Lansing Delta Township Body Shop layout from concept through start of production (SOP). This greenfield project was the 1^st full 3D FactoryCad virtual layout within General Motors.   Received award and recognition as the leanest facility layout within General Motors. Project scope was $265 million for four year project that was brought in on time and budget.

·         Responsible for interfacing with Conveyor Group, WFG, Site Architect and Tooling Vendors. Utilized “virtual fly-thru’s” to run interference checks. 

·         Established preliminary to final processes for many of the assembly systems and conveyor systems in the Body Shop. As-built condition for the Body Shop. Reported to Program Design Lead for GM.

·         Participated in GM FactoryCad Users group, which met monthly to discuss issues within the design community at GM. FactoryFlo utilized at GM for Lambda Bodyshop.

·         Managed $2.3 million project to retrieve 3-Dimensional data via electronic point cloud for body shops and general assembly areas in GM-North America.

·         Established a retrievable database for remote field checking for IE and future model program purposes. Oversaw creation of GM object library, which standardized common reference objects for all GMDI participants to eliminate redundancy, design errors and time delays

 

  9/2002-3/2003           G-Tech , Dearborn MI

                                    Project Engineer- Conveyor Lead (3D Deployment Team GM onsite)

·         Modeled and field checked existing automotive conveyors (body shop and general assembly) from 2D AutoCad to 3D FactoryCad Conversion Project objects. Handled multiple plants:  Orion, Wilmington, Arlington, Janesville, Flint, Lansing Grand River, and Ft. Wayne.  Oversaw other modelers (team of 5) and executed buyoffs with each plant for conveyor models. Project Scope was $3.4 million for North America.

  2/1994-11/2001         Act-1 Engineering, Livonia MI

                                    Engineer- Layout Coordinator (Ford Motor onsite)

·         Created process and conveyor layouts, conducted field checks for future model program layouts for Wixom, St. Thomas, Michigan Truck, St. Louis, Kentucky Truck, Kansas City, Flatrock, Dearborn, Norfolk, from strategic intent to Job 1.  Established the Best Practice Body Shop for Ford Production System Group.

·         Layout Engineer Lead for Factory Cad 3D development. Oversaw conveyor object design and implementation in AutoCad software. Maintained liaison with software developer to bring software online ahead of schedule, saving $1.1 million in development budget.

·         Layout Engineer Lead for Mustang Bodyshop at AAI. Brownfield conversion of Mercury Cougar assembly area to produce current model of Mustang. Included infrastructure changes (Support steel, HVAC, Electrical, Water/Sewer) as well as new Framing system utilizing Dimensional pallets (now the standard for all Ford plants). Scope of project totaled $220 million with a projected savings of $28 million.

 8/1989-2/1994            Borite Manufacturing, Madison Heights MI

                                    Machinist, Journeyman

·           Responsible for production of Hi-speed boring and milling tools utilizing manual and CNC driven equipment (i.e. Vertical Mills, Screw Machines, Lathes, Centerless grinders and vertical grinders). Various materials used including Hi-speed steel, carbon tips and mild steel. Highly skilled in manual grinding of cutting surfaces and edges utilizing grinding wheels. Also ran and maintained heat treatment equipment (furnaces, oil baths etc.) used for treatment of mild steel blanks.

Education :

BSME- University of Michigan- Dearborn. 3.1 GPA Junior Status

Ford Production System-Lean Manufacturing Certificate

FactoryCad Certified (GM)

FactoryFlo Certified (GM)

Journeyman Machinist

Software Expertise :

AutoCAD 2007, AutoCAD Inventor 3, Mechanical Desktop 6, Architectural Desktop 6, Catia V5, FactoryCad 11, FactoryFLO, Unigraphics NX5, TeamCenter, TcVis, VisView, E-Vis, Mastercam 2.0, Lynx 1.2, Paint Shop Pro, Adobe, Microsoft Office Suite, Standard Work Authoring Tools (SWAT),BMW TaktZeitDiagramm

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