WAYNE S. VILCHUCK, CQE, LSSBB
1307 Kline Court , Bat avia, Illinois 60510
• 630-406-8187 • wvilchuck@aol .com •
An accomplished Engineering professional with over 17 years of exemplary experience in manufacturing, continuous
improvement and quality engineering. Proven expertise in reducing costs and improving quality through the implementation
of process improvement initiatives. A skilled communicator and trainer with excellent analytical and problem solving ability.
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Kaizen Team Leadership
Continuous Improvement Programs
5S, Lean Manufacturing & Visual Factory
SPC, Six Sigma, GD & T Methodologies
Plant Layout-Redesign
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ISO 9000-2000/TS 16949
Manufacturing Engineering
Project Management Lead
Capital Improvements
Senior Quality Engineer
Lean Six Sigma Black Belt, Villanova University
Lincoln Foundation for Performance Excellence (Baldrige), Senior Examiner
B.S., Mechanical Engineering, University of Illinois at Chicago, Chicago, Illinois
BISON GEAR & ENGINEERING CORP., St. Charles, Illinois
An industry leader in providing power transmission solutions throughout the world.
2005 to 06/2009
Quality Improvement Coordinator:
Reported to the Process Improvement Manager Responsible for plant-wide continuous improvement, Lean Manufacturing
and Six Sigma projects in the manufacturing of fractional horsepower gear motors.
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Trained manufacturing, office and management personnel in 5S/Lean Manufacturing and Visual Factory Management.
Performed and analyzed time studies and changed assembly and machining operations to improve quality and
productivity.
 Worked with department managers in the writing and implementing of processes needed for Lincoln Foundation for
Performance Excellence (Baldrige) criteria.
 Wrote procedures and performed audits in preparation of ISO 9000 certification.
Continuous Improvement
 Lead Kaizen teams to remove waste in assembly, machining, stockroom and finished goods areas, improving
throughput by 10%.
 Redesigned assembly, machining, stockroom and finished goods areas.
 Implemented 5S program throughout the plant to reduce setup times by 50% and improve work flow.
- Implemented auditing program to ensure continued improvement.
 Redesigned tooling and fixtures to reduce or eliminate setups.
 Responsible for monitoring all plant wide improvement suggestions and ensuring effective closeout.
Six Sigma Black Belt
 Improve Cpk of machining line from less than 1.0 to over 1.5 and improved internal quality, reducing warranty returns
by 40%.
 Improved productivity in gear machining process by 6%.
 Reduced setup times for machining process by 50%.
DUPAGE MACHINE PRODUCTS, Bloomingdale, Illinois
A machining company specializing products for the hydraulic and automotive (Tier 2) industries.
2003 to 2004
Quality Manager:
Reported to the President Responsible for the maintenance of the quality system to ISO 9000-2000 and to comply with TS
16949.
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Expanded the use of SPC in machining, grinding, honing and assembly operations to improve product quality and
trained supervisors and operators its use.
Using Six Sigma methodologies led teams in the improvement of machining capabilities, reducing setup times and
reducing scrap/waste.
Trained Machine Operators, Quality Technicians and Engineers in GD&T; supervised 4 quality technicians.
WAYNE S. VILCHUCK, CQE, LSSBB
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CATERPILLAR, Aurora, Illinois
2000 to 2003
The world's largest manufacturer of construction and mining equipment, diesel/natural gas engines and industrial gas turbines.
Senior Manufacturing Engineer:
Reported to the Advanced Manufacturing Manager Responsible for the day-to-day operations and long term planning of
axle assembly and machining areas to reduce work in progress (WIP), eliminate non-value added activities and improve
process from batch flow to one piece flow (Lean Manufacturing).
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Responsible for all aspects of project management from justification of capital expenditures to equipment installation
and startup.
As a Six Sigma Green Belt, worked with numerous Six Sigma Teams, most notably in reducing costs machining and
assembly scrap costs ($50k per year in savings).
Worked with design personnel in the identification of warranty/reliability concerns.
EATON HYDRAULICS, Carol Stream, Illinois
A supplier of hydraulic components for the heavy equipment, agricultural and truck/automotive industries (Tier 2).
1997 to 2000
Quality Manager/Senior Quality Engineer:
Responsible for managing the quality activities for both the Carol Stream and Petersburg, Illinois manufacturing facilities.
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Led Six Sigma teams to improve manufacturing capabilities
- Improved first pass yield product line from under 90% to over 99% and reduced warranty returns.
Led Kaizen teams in the implementation of Lean Manufacturing.
Transitioned quality system from ISO 9000 to QS 9000.
Worked with team members in outsourcing of all operations from the Carol Stream plant to the Reynosa, Mexico
facility.
Supervised 5 Quality Technicians.
BORG WARNER AUTOMOTIVE, Dixon, Illinois
A Tier 1 manufacturer and distributor of automotive engine components.
1995 to 1997
Manufacturing/ Quality Engineer:
Responsible for managing all manufacturing and quality concerns in the production of automotive engine components.
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Setup new and redesigned existing assembly and machining processes to improve capabilities, eliminate 100%
final product testing or to reduce manufacturing costs.
Provided pivotal assistance in the designing, implementation and auditing of quality system in the achieving of
QS 9000 certification.
Responsible for PPAPs submissions and customer specific change documents and monitored their status until
completion.
Worked with team members in the outsourcing of machining and stamping products and equipment.
NOBERT PLATING COMPANY, Chicago, Illinois
1993 to 1995
A company specializing in plating for the automotive (Tier 1 and Tier 2), communication and electrical distribution industries.
Quality Assurance Manager:
Responsible for overseeing all aspects of a multi-plant plating company.
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Supervised department of 7 Inspectors/Technicians.
Responsible for startup and implementation of ISO 9000.
ITW SHAKEPROOF (a division of Illinois Tool Works), Elgin, Illinois
1992 to 1993
A leading supplier of fasteners and engineered metal stampings to automotive (Tier 1) and industrial products industries.
Quality Engineer:
Responsible for coordinating the QA activities in the manufacturing of fasteners and stampings.
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Wrote and implemented ISO 9000 procedures.
Responsible for plant on-line SPC program and GP-3 submissions..
WAYNE S. VILCHUCK, CQE, SSBB
U.S. AIR FORCE, Fairchild Air Force Base, Washington
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1986 to 1992
Captain:
Supervised the training of 40+ personnel in electronic warfare and defensive tactics and directly supervised 7 personnel in
the maintenance of simulators.
EDUCATION
B.S., Mechanical Engineering, University of Illinois at Chicago, Chicago, Illinois
Graduate Studies, Washington State University, Spokane, Washington, 1990 to 1991
LICENSES/CERTIFICATIONS
Certified Quality Engineer
PROFESSIONAL DEVELOPMENT
Lean Six Sigma Black Belt, Villanova University, 2008
Lincoln Foundation for Performance Excellence (Baldrige), Senior Examiner Training, 04/2006, 06/2007, 06/2008, 06/2009
Six Sigma Green Belt, Caterpillar University, 2002
Eaton Business Excellence Award Examiner, 2000
Perry Johnson Inc., QS 9000 Internal Auditor Training, 1997
Perry Johnson Inc., ISO 9000 Internal Auditor Training, 1994
MEMBERSHIPS/AFFILIATIONS
American Society for Quality (ASQ)
Society of Manufacturing Engineers (SME)