Donald Burns

1824 Aspen Pines Drive, Wilder, Kentucky 41071

408.239.7223
d.patburns@gmail.com

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

AREAS OF EXPERTISE
LEAN MANUFACTURING ~ TEST AND QUALITY ANALYSIS ~ EQUIPMENT AVAILABILITY IMPROVEM
ENT ~ DEFECT AND COST REDUCTION ~ MODEL-BASED PROBLEM SOLVING ~ STATISTICS / PRO
CESS CONTROL ~ QUALITY, SAFETY, AND ENVIRONMENTAL COMPLIANCE ~ PROCESS IMPROVEME
NT

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⠬Â
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