ROBERT M.

MELBY
2106 Riviera Dr.
Racine, Wisconsin 53406
(262) 886-1855
melby.robert@yahoo.com

BACKGROUND SUMMARY

Senior Tooling Engineer/Tool and Die Professional with expertise in

process improvement, trouble shooting capabilities, and new product
launches – global, domestic, large and small size companies. Excellent
decision making, critical analysis, problem solving and communication skills.
Proven expertise in:
· Design and Build · Continuous Improvement
· Project Management · Tool Estimating
· Operator Training · Process Engineering
· Lean Manufacturing · Product Development

PROFESSIONAL EXPERIENCE

MODINE MANUFACTURING COMPANY, Racine, Wisconsin 1986 to 2009

$1.8B global manufacturer of innovative heat transfer solutions for the heavy truck, automotive,
agricultural, construction and HVAC&R industries. Headquarters located in Racine, WI, USA.

Senior Tooling Engineer 2004 to 2009

Responsible for new product launch process including review of
application design, cost estimation, purchasing, supplier selection,
design specification, installation and training.

• Coordinated with purchasing to identify a stamping supplier to produce parts resulting in

$1.3 million savings from original estimates over life of program.
• Re-engineered key part for customer product, saving $1 million by reducing scrap and
improving manufacturing process.
• Spearheaded project to introduce process to accommodate high volume part production,
eliminating four separate operations and improving processing time 90%.
• Collaborated with plant associates to improve product throughput by evaluating current
manufacturing processes eliminating wasted motion.
• Traveled to manufacturing and supplier sites to trouble shoot new
equipment to ensure tools ran at specified production rate.
• Used trouble shooting skills to resolve issues with existing equipment.
ROBERT M. MELBY
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 Tooling Engineer 1993 to 2004
Completed design and integration of new equipment resulting in 100% payback
over life of program.

Tooling Coordinator 1989 to 1993

Responsible for daily management of new programs: cost, timing and
program coordination.

Journeyman Tool & Die Maker 1986 to 1989

Responsible for design and building class “A” dies and specialty machines.

Held progressively responsible positions as Journeyman Tool and Die Maker Prior to 1986
for the following companies:

Eckmann Pressed Metal Company

Triple E Corporation
Sterling Tool Company

EDUCATION
Apprenticeship, Gateway Technical School, Racine WI

CERTIFICATIONS
State Certified Journeyman Tool and Die Maker

TRAINING
Advanced Product Quality Planning
Society Manufacturing Engineers “Stamping Die” Certification
Managing Multiple Projects, Objectives and Deadlines
Value-Based Management
How to Become a Better Communicator
Introduction into Fineblanking Technology
Power Press & Machine Safegaurding
Continuous Improvement Training in Single Minute Exchange of Die and Value Stream Mapping

COMPUTER SKILLS
Microsoft Office, Solid Edge

PATENTS PENDING
Multi-Passing Liquid Cooled Charge Air Cooler with Coolant Bypass Ports for Improved Flow
Distribution, Serial No. 11/430,440 Filed 5/9/2006
Stacked/Bar Plate Charge Air Cooler Including Inlet and Outlet Tanks, Serial No. 11/838,809 Filed
8/14/2007