Published on January 29, 2016
1. Senior Manufacturing Engineer Gar E. Cooley 2531 Pin Oak Drive York, PA 17406 Garcooley56@gmail.com 717-434-4445 Summary: • Robotic Paint Process Professional with 25 years of experience in the automotive and industrial market. • Process optimization through data gathering and continuous improvement. o Familiar with WinSPC configuration and implementation. o FMEA software experience • Process development and validation using Minitab and WinSPC • Specialist in maintaining and optimizing process. • Extensive paint fixturing and tooling development/maintenance experience • Responsible for the installation and configuration of automated robotic paint systems. Program paths to achieve process goals and cycle times. o ABB installation and test engineer for 10 years Installed complete automotive paint line systems with up to 8 robots in a single booth Performed field service work repairing down robots o Fanuc RJ3i and P250 training at Fanuc school in Toledo, Ohio o Kuka KRC 4 and KR30 HA training at Kuka robotics in Shelby Township, MI o Extensive hands on experience with Motoman MRC SK 16 • Knowledgeable in all areas of paint shop applications. Able to meet process specifications for paint application and quality. • Coordinate activities with sub-contractors and maintenance personal to meet schedule deadlines and maintain uptime. • Assist Controls and GUI engineers in configuring the system per proposal and applicable regulations. • Assure customer satisfaction. • Possess excellent communication / interpersonal skills and in depth project management experience. Employment experience:. Employment: 9-11-2011 – 10-30-2015 Sr. Manufacturing Engineer Harley-Davidson • Paint Finesse Engineer o Robotic pin striping
2. Process improvement through stripe gun component upgrade and replacement. Added serial number information to wear items on the stripe gun components to establish service life and validate warranty information Paint re-formulation for more robust process and to improve first time quality Paint stripe fixturing PM implementation to improve uptime and first time quality Improved lighting in the work areas for operator inspection of finished parts. Used 6500K bulbs for improved color recognition, Added more light fixtures in the inspection areas. Added detail to standard work instructions to clarify process for operators o Decal application Extensive effort to establish process controls and improve quality of vendor supplied components. • Worked with plant engineers to improve the temperature controls on the dehydration machine used to “cure” the decals Added additional work instructions to standard work to improve application quality and reduce application times Fixture re-work to improve first time quality Added more light fixtures for improved visibility during application Did extensive research to determine least impactful application techniques to reduce hand, wrist, arm, and shoulder injuries from repetitive motion o Masking for tu-tone paint styling Improved standard work for application of pre-cut masking components for Tu-Tone paint application. Developed improved taping process to reduce the size of the parting line between the primary and Tu-Tone layers of paint o Installed and started up new Kuka robotics pin striping cell. Heavily involved in the design and development of tooling for the indexing dial on the cell. o Managed ordering of production supplies, decal deliveries, stripe paint ordering, stripe gun replacement components. o Added several items to the plant “stock room” to reduce manual ordering of parts • Wetspray Engineer o Responsible for daily operation of two robotic paint lines (4 robots each line) applying color on one line and clearcoat on the other. Added improved process for paint circulation systems to control paint circulation rates at manufacturers recommended rate. Removed extraneous equipment from the circulation systems to improve system flushing times and reduce solvent usage. Led team that identified conveyor posts condition as root cause in poor first time quality due to bent and damaged posts. This led to completely replacing all posts en masse. This improved part
3. presentation/repeatability and lead to higher throughput and first time quality • Project manager o Harley-Davidson certified in project management Reliability based equipment replacements in E-coat and powder systems • Replaced Phosphate bath Oberlin filter • Replaced old and damaged E-coat fixturing for tanks and fenders Added “divider” to shipping containers for swingarms to reduce damage during shipment and reduce operator effort in removing swingarms from containers. • Harley-Davidson certified Six Sigma Yellow Belt 9/2009 - 3/2011 Paint Process Engineer Western Extrusions Corp • Redesigned tooling to increase density of parts on line • Added process controls for paint flow • Fixed booth air imbalance for increased transfer efficiency • Located paint oven leaks using DataPaq ensuring product cure to manufacturer specification • Added work area tool sets for equipment maintenance and improved uptime • Added paint system flushing to regular weekly maintenance PMs 3/2005 - 9/2009 Owner - General Automation and Robotics LLC “Working in the automotive industry as an independent paint process consultant and industrial robot programmer” • Working as sub-contractor for Autoquip, installed ITW rotary atomizers in Harley Davison "old" paint shop in York, PA • Working as sub-contractor for Autoquip, made programs for new Harley Davidson "Rocker" model on new paint line at Harley Davison "Softtail" plant in York, PA • Received training at Fanuc in Toledo for new p250 manipulator and controller • Optimized paint process and path programs in various tier 1 automotive supply plants • Installed Fanuc P-250 automated system in Emerson Electronics plant in Rushville, IN • Optimized paint process in numerous tier 1 supplier paint shops 2000 - 3/2005 Test / Installation Engineer, ABB Flexible Automation Responsibilities: • Install and debug automated robotic paint systems.
4. • Program paths to achieve process goals and cycle times. • Meet process specifications for paint application. • Coordinate activities with sub-contractors to meet schedule deadlines. • Assist Controls and GUI engineers in configuring the system per proposal. • Assure customer satisfaction. Major Accomplishments: • Managed site installation / start up, path programming, and process validation for the new paint shop at Chrysler St. Louis North Assembly plant. • Completed IPS Expert training course in Norway. • Lead robot tech on Honda Marysville paint projects 2003/2004 1998 - 2000 Field Service Engineer for ABB Flexible Automation Responsibilities: • Repair out of production robots used for welding and paint application. • Install and program robots as sold by the Aftermarket Division • Sell programming and software / hardware upgrades for existing robot installations. • Install and configure software / hardware upgrades for existing robot installations. • Execute specialized programming for soft air push, color change control, and degrade modes. • Install and configure CAP software. • Assure customer satisfaction. Major Accomplishments: • Successfully re-established ABB as a viable and reliable vendor in the Chrysler St. Louis North Assembly plant. • As an individual, unsupervised operator for CSD generated $196,000 revenue in one year by obtaining contracts from the customer for continuing work. 1998 Test / Installation Engineer, ABB Flexible Automation Responsibilities: • Install and debug automated robotic paint systems. • Program paths to achieve process goals and cycle times. • Meet process specifications for paint application. • Coordinate activities with sub-contractors to meet schedule deadlines. • Assist Controls and GUI engineers in configuring the system per proposal. • Assure customer satisfaction. Major Accomplishments: Single handedly installed, debugged, and programmed robots in North and South America. 1992 - 1995 Plant Supervisor, Rodgers Finishing Tools, Lebanon, Ind.
5. Responsibilities: • Generated all production schedules. • Controlled hiring and firing of all floor personnel. • Ensured that the plant operated within all OSHA guidelines. • Controlled quality of manufacturing, set standards for future production. • Responsible for the finishing, crating / shipping of all finished product. Major Accomplishments: • Improved existing product line through better manufacturing techniques and improvements to existing designs of components. • Operated "on time" and "on" or "under" budget. • Successfully integrated Fanuc P100 robots with Rodgers pneumatically controlled indexers. 1988 – 1995 Owner, Cooley Construction, Indianapolis, Ind. Responsibilities: • Generated all proposals, schedules, materials lists • Controlled hiring and firing of all personnel. • Ensured that the company operated within all OSHA guidelines. • Ensured customer satisfaction. Major Accomplishments: • Built the largest wood frame structure in Hamilton County Indiana. • Designed all residential structural re-model projects.
6. Education: 6/73 Pike High School, Indianapolis, Indiana 6/74 IVY Tech, drafting course 6/76 IUPUI Indy campus Selected courses relating to Drafting / Mech. Eng Completed Allen Bradley 6200 programming course for PLC5 Fanuc Robotics P250 training course 2007 Fully trained and certified by ABB Flexible Automation in programming and repair of ABB Paint robots Private Pilot SEL rating w/ conventional gear endorsement
7. Education: 6/73 Pike High School, Indianapolis, Indiana 6/74 IVY Tech, drafting course 6/76 IUPUI Indy campus Selected courses relating to Drafting / Mech. Eng Completed Allen Bradley 6200 programming course for PLC5 Fanuc Robotics P250 training course 2007 Fully trained and certified by ABB Flexible Automation in programming and repair of ABB Paint robots Private Pilot SEL rating w/ conventional gear endorsement