1. Gerald D. Faust
108 Roth Road, Kempton, Pa. 19529 cell #610.349.3772 Email:coachdanf@yahoo.com
Objective
Seeking a Manufacturing Engineer position in a company where I can continuously improve the
effectiveness and efficiency of the company while maintaining safety, by using the vast skill sets
I have acquired.
Lean Manufacturing
• Lean Manufacturing Core Team member of ‘Lean Initiative’ – a value stream mapping process
that produced a production cycle time reduction from 8.3 weeks down to 5.2 weeks which equates
to 2055 DL hours reduced to 1238 for an estimated DL savings of $1.1 M/yr.
• Applied multitasking capabilities to create work cells and relocate KanBan bins to improve
manufacturing efficiency; i.e. controller assembly decreased 3.5 hrs per build after implementing.
• Expressed confidence in implementing a 3 bin Kan Ban system which reduced picking time by an
average of 14% and reduced quantity of P/Os by an average of 8% a month.
• Performed quarantine builds to identify inaccuracies in documentation, BOMs and routings.
Cost Reduction
• 1 of 3 members on solar tool system cost reduction team reduced overall cost from $1.3 M/system
down to $855,000/system via innovative design changes and new manufacturing processes.
• Initiated and conducted the re-sourcing of chuck bearings to new supplier and monitored design
changes which reduced cost from $5200/bearing to $1274/bearing with improved “MTBF”.
• Conceptualized an ERP report to generate manufacturing drawing lists per work order. This saved
an average of 2 hours per tool.
• Generated RMAs and worked with suppliers to reduce supplier defects by an average of 18%.
Problem Solving
• Incorporated innovative layout concepts, as main office increased from 50 to 500 employees, on
teams to re-layout the production areas in times of expansions and times of consolidation.
• Active member of a cross functional team to merge ERN, ECO and ECR into one document as
Phase I and Phase II the team reduced ERN processing times from 5 days to 2 days on average.
• Orchestrated the implementation of a plastic pipe butt welder to enable production to build
assemblies in house and reduced cost of assemblies by an average of 11%.
• Showed perseverance in spearheading the feasibility of purchasing a CNC router table; it was
determined to be not feasible thus saved the company a minimum of $80,000 in upfront costs.
• Supported teams to receive three separate product lines from competitors we purchased in Idaho,
California and Germany.
• Reduced weekly redline drawing generation of 40/wk average down to 12/wk by implementing a
system of ‘working floor redlines’.
Management
• Compiled information to construct monthly KPI reports for VP of Operations.
• Supervised and trained the plumbing department and later the MFE department.
• Exercised strong communication and leadership skills on PACE teams for design of new options.

2. System/Process Creation
• Constructed a plug & play options based ordering system for our main product line which
standardized the product line and simplified configuring a bench system from 30 hours to 8 hours.
• Developed a program to streamline changing a part from Buy to Make, setting a part as Kan Ban
and changing assembly to a phantom; on average 2 days reduced to 21 minutes per task
• Produced a system to simplify the hundreds of duplicate part numbers, due to merging multiple
part numbering systems, which took processing a duplicate from 3 days to 14 minutes per entry.
• Fabricated a process for legacy drawing redlines, that we were not capable of modifying, which
allowed production, purchasing and engineering to work from accurate drawings.
Skills
• Liaison between manufacturing and engineering for issues that arose during production cycle.
Evaluate and resolved issues in a timely manner in order to minimize downtime.
• Conducted Make/Buy analysis to determine if assemble was a viable candidate for outsourcing.
• Refined AutoCAD skills by designing fixtures to aid in assembly times and improve accuracy.
• Utilized the Project Tracker System to track issues in production, determine the root cause and
ensured the issues were resolved completely.
• Evaluated outsourcing of build to print plenums to Mexico, Europe and nationally.
• Created working assembly procedures and inter-departmental procedures.
Professional Experience
Akrion Systems, Allentown, PA Nov 1991 – April 2016
Manufacturing Engineer, Flow System Supervisor, Flow System Technician
Vista Scientific Corporation, Ivyland, PA May 1988 – Nov 1991
Field Service Engineer
Lehigh John Deere, Allentown, PA Summer 1986
Mechanic
Education and Training
Pennsylvania State University, State College, PA May 1988
B.S. in Agricultural Mechanization
Delaware Valley Industrial Resource Center, Philadelphia, PA May 2004
Kaizen Training
Leadership Management International, Whitehall, PA Nov 2003
Lean Training – Value Stream Mapping, 5S and Kaizen principles
Effective Supervisory Management Course
Synergis, Quakertown, PA Nov 1995 & June 2002
AutoCAD 12 & 2000
Lehigh County Community College, Allentown, PA March 1994
Leadership, Team Building & Management Courses
Akrion Systems, Allentown, PA July 1994
ISO 9001 & 14001 Training