T.J. Cook
Lead Manufacturing Engineer
Irvine
Summary
High-Performing Manufacturing Engineering Lead with proven ability in all skills required through full Product Life-Cycle deployment, for complex products; optimizes from a leader's perspective across the global set of business success criterion to execute high-impact solutions. Seeking role in US Tech-based organizations with broad-scope, fast-paced, and highly cross-functional workflows with appropriately accelerated paths to career advancement. Target industries incl. Aerospace, Astronautics, Defense-Tech. Target locations incl. West-Coast and Texas.
Overview
8
8
years of professional experience
Work History
Lead Manufacturing Engineer
Mach Industries, Inc
03.2024 - Current
- Hired, trained, and managed small team of engineers to deliver on Manufacturing needs for the organization
- Produced labor estimates and detailed OPEX and CAPEX cost estimate models for all product lines, factory headcounts approaching 150+
- Managed and executed Concurrent Engineering DFM&A studies on Mach's two main products, from conceptual through prototype level maturities
- Designed and deployed Jira project to manage prototype builds and fab-requests; central location for work instructions, vehicle build schedule, parts fabrication requests, defect reports, planned concessions, etc.
- Completed AutoCAD layouts for mass-production lines
- Managed prototype operations team to ensure Manufacturing output meets or exceeds expectations of design engineering; ensures attribute validation testing is not impacted by manufacturing errors and errors where identified are captured thoroughly in our Jira system. Prototype Ops includes: Additive shop, fabrication, composites, CNC, and Paint.
- Developed manufacturing part traceability requirements
- Actively managing deployment of Siemens Manufacturing PLM modules within Mach; MBOM, BOP setup
- Procured initial factory inventory mgt. and asset tracking software
- Leading procurement for factory MES, considering short and long term organizational needs; compatibility with interfacing softwares (ERP, EMS, APS, etc), for both startup oriented (Manufacturo, Ion, Tulip) and Legacy (Siemens OpCenter, Rockwell etc.) software providers
Senior Manufacturing Engineer, DFMA
Rivian Automotive Inc.
04.2023 - 03.2024
- Lead Low-Voltage Electrical (LVE) DFMA activities across all future Rivian programs (EDV, R1 Mid-Cycle Actions, and beyond) from design inception through series of Prototype Asset Build events leading up to the first Manufacturing Validation Build event held at the factory
- Events Hosted: Amazon Delivery Van, and R1 Mid-Cycle Action Virtual Builds (x3), and corresponding Design Validation Builds (x4)
- Established first set of LVE DFMA standards published to Official Rivian Design Standards; data structure for feas. BOP integration, CAD Modeling standards, acceptable path bend-radii, LVE ground anti-rotation strategy to min. residual torque load
- Developed x-functional strategy to efficiently track and maximize re-utilization of ME team outputs to minimize workload caused by high-frequency design iteration, minimizing re-work and lead time of DFMA analyses; part bank, equipment bank, event-bank tree structures through Atlassian software suite
Senior Manufacturing Engineer
Rivian Automotive Inc.
03.2021 - 04.2023
- Responsibilities: full ownership of GA ME overhead planning / deployment process through 2.5 yr program lifecycle, from design content conceptualization through SOP Ramp and handoff to plant ownership, all EDV variants for Flat-Top Final Line; 85+ parts, 17+ equipment deployments
- Equipment deployments include seven high-complexity dynamic fluid fill systems requiring orchestration of vehicle thermal control systems mid-cycle, plus Class 1 Div 2 flame-mitigation zone equipment, keyfob etching, and keyfob flashing equipment (PM only).
- Successfully met MVB + SOP timelines through high-frequency coordination between x-functional internal/external teams: Studio, Product Dev/DREs, Program Management, Packaging, Dunnage Design, Layout Engineering, Plant OPS, Plant Process Eng, Facilities/Utilities, Vehicle Thermal Controls, Plant Controls, Plant Maintenance, Plant IT, Plant Quality, Equipment Vendors, EHS, Ergonomics Team, State Governmental Bodies incl. Fire Marshal
- Led GA ME engineers as EDV RHD Manufacturing Engineering Program Champion: managed RHD GA Virtual Build with 75+ x-functional attendees, and 16-unit RHD Design Validation Build, generating 105+ 'Rivian Concern' Tickets to drive subsequent investigation and root-causing of issues prior to Manufacturing Validation Build Phase
- Co-inventor, patent-pending conveyance design to eliminate AGV (incl other discrete conveyance unit types) charging loop infrastructure from EV conveyance; reduced expected deployment time, risk, ~$3m cost reduction
- Project managed development, deployment, and fleet management of in-house AI-based camera defect and process state recognition deployment; $12M+ in minimum validated savings to date; deployments in Body, Paint, GA-Chassis, GA-Trim, GA-Final, EOL-Test, and EOL-Repair departments
- Designated MODAPTS PMTS team trainer
Manufacturing Engineer
Rivian Automotive Inc.
08.2020 - 03.2021
- Virtual DFM/DFA Validation & Optimization
- Virtual Validation of Manufacturing Processes
- Equipment/Tooling Planning & Procurement
- Labor Allocations & Optimization (PMTS study-based)
Industrial Engineer
Rivian Automotive Inc.
11.2019 - 08.2020
- EHPV, HPV Estimation and Costing
- Capacity planning, labor studies (MODAPTS) / headcount estimation, verification of integrator studies
- Program Change Cost studies
- Drive Unit and Inverter Line throughput, buffer optimization through appropriate interpretation of Discrete Event Simulation reports
- RFQ Gear Wash System; determined RFQ system requirements to satisfy ISO cleanliness standards specs, throughput, plant, and process constraints
Business-Unit Industrial Engineer
Leggett & Platt, Inc
01.2018 - 10.2019
- Leggett & Platt, Inc is a global manufacturer of various engineered products with 23,000 employees operating across 15 business units and 18 countries. Product offerings include consumer products, automotive sub-assemblies, and aerospace tubing. They are the market leader in Adjustable Bases for consumer and medical applications
- L6S Black Belt Project: Successfully implemented project saving $90k in labor over two months with annual savings of $140k; Identified performance gaps in new production line underperforming at 1.12; MH/Unit average with calculated capability of 0.74 MH/Unit; Managed indirects to achieve resolution of issues
- NPI Activities: Supported four domestic and one international location performing pre-production activities with key personnel; launched 150 SKUs
- Time Studies: Performed 80+ time studies across entire spectrum of value stream for costing and CI purposes
- Accomplishments: Standardized department's time study/work analysis; trained local engineering on video capture methods & correct use of TPP software; developed pre-determined motion time system for rapid, efficient cost-estimation
- Continuous Improvement Initiatives: Reduced welded frame shipment & storage costs by 75% via stack pattern optimization + pallet redesign, saved $170K in international freight over 2 mos, reduced floor space occupancy by $60K across all sites
Factory CI/Industrial Engineer
Leggett & Platt, Inc
01.2017 - 01.2018
- Work Design and Measurement (time studies, MOST, etc.); Ergonomic Risk Assessment (NIOSH, RULA, REBA, etc.); Executed 25+ costing analyses
- Lead initial floor design, location selection, and planning for new dedicated line for single product group
- Managed integrator relations for launch of two automated lines
- Negotiated project timeline and pay structure ($500k Capital Investment)
- Assisted with new facility ramp-up on first two semi-automated assembly lines
- Utilized DOE tools to design experiment to test multiple shipping configurations through multiple route options based on data acquisition costs
Education
B.S. Industrial Engineering, Bus. Management Minor -
Purdue University
West Lafayette, INL6SBB - L6S Black Belt Certification
Nexus Lean Six Sigma, Leggett CI Division
Skills
- 3DE- Delmia, Catia, Enovia PLM Suite
Minitab - Hypothesis Testing, Multiple Regression, DOE, Distribution Fitting, etc
DES Modeling - Simio, Arena
Snowflake, SQL, Microsoft Access
AutoCAD 2D Layouts
Affiliations
- Originating member of FIRST Robotics Team 2834 starting in 2009; the succeeding team proceeded to win 2018 Chairman's Award to enter FIRST's Hall of Fame Roster
- 2018 - continuing: FIRST World Championship Volunteer Field Reset Crew
- 2011 - 2020: Institute of Industrial and Systems Engineers Member- IISE is the premier society for Industrial and Systems Engineers worldwide
Timeline
Lead Manufacturing Engineer
Mach Industries, Inc
03.2024 - Current
Senior Manufacturing Engineer, DFMA
Rivian Automotive Inc.
04.2023 - 03.2024
Senior Manufacturing Engineer
Rivian Automotive Inc.
03.2021 - 04.2023
Manufacturing Engineer
Rivian Automotive Inc.
08.2020 - 03.2021
Industrial Engineer
Rivian Automotive Inc.
11.2019 - 08.2020
Business-Unit Industrial Engineer
Leggett & Platt, Inc
01.2018 - 10.2019
Factory CI/Industrial Engineer
Leggett & Platt, Inc
01.2017 - 01.2018
B.S. Industrial Engineering, Bus. Management Minor -
Purdue University
L6SBB - L6S Black Belt Certification
Nexus Lean Six Sigma, Leggett CI Division
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