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Donald Burns 1824 Aspen Pines Drive, Wilder, Kentucky 41071 408.239.7223 d.patburns@gmail.


PROCESS ENGINEER PROFILE OVERVIEW Thorough and quality-focused professional with well-rounded experience in the ma nufacturing industry and advanced technical proficiency in assembly, paint, stam ping, and quality engineering. Skilled and systematic in providing leadership to multi-disciplinary integrated tasks, ensuring effective application of quality assurance procedures, and developing lean manufacturing procedures to reduce cos t and maintain efficiency in equipment and system maintenance. Collaborative and capable of building a cohesive work environment with suppliers, vendors, contra ctors, and cross-functional teams. Highly analytical and innovative with results -based experience in leading upscale volume of projects and in resolving issues with precision and commitment to excellent service. Technical skills include but not limited to: Failure analysis of Paint Coatings with Scanning Electron Microscope (SE M) and FTIR analytical equipment PeopleSoft 8, Microsoft Excel, Word, and PowerPoint, Lab Information Man agement System (LIMS) Simul8, Unigraphics, Catia, AutoCAD, Inventor, Finite Element Analysis, Ideas, and Maximo Automotive mechanical and electrical systems (Drivability diagnosis, OBD I &II, A/C, brakes, and Suspension) Atlas Copco Tensor Tools


PROFESSIONAL EXPERIENCE Toyota Motor Engineering & Manufacturing North America (TEMA), Erlanger, KY MATERIAL QUALITY SPECIALIST JUL 2009-PRESENT Oversee and develop quality management solutions for all exterior paint material quality issues for Toyota Motor Manufacturing Indiana (TMMI). Manage and lead t he resolution of all Electrodeposition (E-Coat) material quality issues for all plants in North America. Direct and streamline containment, analytical analysis, root cause, and recurrence prevention procedures of major paint quality problem s at TMMI. Proficiently managed process change requests with suppliers resulting in reduction of quality risks Reduced cost by $176K by not scrapping paint bodies through providing an alysis of phosphate condition with a scanning electron microscope Improved key performance indicators with supplier improvement activities

(audits, supplier performance data analysis) Toyota Motor Manufacturing Mississippi (TMMMS)-Georgetown, KY PAINT MANUFACTURING SPECIALIST Jul 2008-Jul 2009 Trained at new 3-wet paint department at Toyota Canada Plant (TMMC) and benchmar ked processes at Toyota Georgetown KY Plant (TMMK) for new Toyota Mississippi pl ant (TMMMS). Appointed as a project manager for paint transfer efficiency Kaizen feas ibility trials, which resulted in achieving 29% paint reduction and $800K annual savings for Clear Coat per plant at (TMMK) Reduced ergonomic conflicts on team members while adding process quality through research and trial of Bluetooth Atlas Copco tensor on moon roof line at TMMK New United Motor Manufacturing, Inc. (NUMMI) GM and Toyota Joint Venture-Fremont , CA STAMPING MANUFACTURING SPECIALIST Jul 2007-Jul 2008 Developed and implemented cost saving strategies for seven stamping wash oil sys tems and initiated improvement in existing plant procedures to ensure safe and h azard-free work environment. Efficiently set up systems to add proper wash oil concentration additive s and improved filtration efficiencies, which resulted in reducing operational c ost Strategized a cost saving gravity filtration method for wash oil, projec ting a $50K possible annual savings Improved the process in tracing off foreign material in a stamping die t hrough the development and implementation of the first defect analysis tool with florescent dye which also ensures $500K annual cost side member defect Designed and implemented new low atomization wash system component on bl anking line that increased workplace safety and reduced wash oil cost Toyota Motor Manufacturing Indiana (TMMI)-Princeton, IN ASSEMBLY MANUFACTURING SPECIALIST Oct 2006-Jul 2007 Spearheaded a project for material handling equipment installation for Tundra la unch: Center Pipe Delivery System and Dolly, Automated Transmission Delivery Sys tem, and Tail Pipe Rack. Designed, managed and maintained efficiency in the entire project lifecy cle of a new V-6 sub-assembly production area with pokeyoke system for new Tundr a launch while ensuring zero downtime at SOP Decreased maintenance cost and downtime while improving safety of truck frame conveyance equipment Toyota Motor Engineering & Manufacturing North America (TEMA)-Erlanger, KY ENGINEERING SPECIALIST Jul-Oct 2006 Chosen to participate in Toyota Engineering Rotational Program comprised of Toyota specific classes.

Toyota Motor Manufacturing Kentucky (TMMK)-Georgetown, KY ENGINEERING CO-OP Oct 2001-Jan 2006 Managed and coordinated more than 80 projects for maintenance, production, safet

y, and environmental issues. Utilized multiple equipment, such as top coat and p rimer spray booths, e-coat, phosphate, sealer, industrial ovens, regenerative th ermal oxidizer, floor conveyances, overhead conveyances, and HVAC systems. Systematized work plans and schedules to reduce production downtime Managed and ensured accuracy in paint maintenance cost tracking records and budget reports

EDUCATION (BS) BACHELOR OF SCIENCE IN MECHANICAL ENGINEERING ~ 2001-2006 Kettering University (Formerly General Motors Institute, GMI)-Flint, MI

Thesis Title: â⠬ŠEvaluate the Feasibility of Recycling Paint Waste at Toyota Motor Manufa turing Kentuckyâ⠬ International Studies Program, Esslingen, Germany (Apr-Jul 2006)

PROFESSIONAL TRAINING Toyota Specific Classes Toyota Fundamentals Toyota Way Foundations Communicating the Toyota Way Introduction to TPS, TPSI and II Introduction to Standardization Standardized Work Hoshin Kanri Anti-Harassment Awareness Diversity I and II Introduction to TBP Introduction to PDCA Project Management I and II Time Management Mentee Training Self Coaching Toyota Business Practices

ACTIVITIES Toyota Motor Manufacturing, Kentucky Plant-Toyota Co-op President / Facilitator (Apr-Jul 2002) Sigma Alpha Epsilon International Fraternity-Treasurer (Apr 2004-Jul 2005) Pledg e Class Vice President