David Zaffino

Starting a new chapter; working for the large truck industry focusing on top quality molds to manufacture headlights, side marker and brake lights, and mirrors. Truck-Lite doe complete product development and testing to supply the full assemblies to all major manufacturers of Over The Road trucks and trailers.

Ci Medical develops medical parts from concept to production. We work with the customer to achieve the most robust product design possible. We manufacture a world class mold to produce the products in one of our four clean rooms, to turn that design into reality. Ci Medical, now part of TECHNIMARK, prides itself on superior quality of every part we produce. No job is too big or small nor are they too complex for us to bring your dream to fruition. We work with world class tool shops using fine U.S. steel to assure the quality of every part we deliver.

Design and build plastic injection molds, sample, and run production for low to high volume products in automotive, consumer, and medical industries. Design and build custom assembly equipment. Design and enhance designs of customers' products for optimum performance and durability.

Evaluate part drawings to establish mold design. Supervise and track progress of design, oversee mold construction and assure milestones are met, attend initial sample and develop plan to meet customer expectations are met, work with process engineering to establish a robust and repeatable process, and work with quality control to assure dimensions and tolerances are held. . Helped complete, sample, and deliver 10 of 19 products to customer that were late. Develop system to increase accountability for critical project milestones. Reduced tool change-over times by 25% by creating instruction manual for family molds and storage system for inserts.

Manage and coordinate work for third shift assembly workers on Lean Manufacturing assembly line. Maintain shipping schedule of finished goods, update incoming product information from internal suppliers, and report daily progress for production control and productivity. Conduct weekly informative safety meetings to all third shift employees. Helped establish Lean Assembly Line for auxiliary cabs for freight locomotives by implementing standard work and material presentation to streamline assembly process. Increased productivity (Takt attainment) by 25% of Lean Line throughout 2008. Reduced first aid injuries by 50% through weekly safety meeting with shift employees.

Manufacturer of plastic automotive interior and exterior components including decorative trim and structural support components.

Scheduled and coordinated all preventative maintenance (PM), repairs, and engineering changes to injection molds using outside tool shops. Generated concepts for new injection mold designs and engineering changes for outside tool shops. Organized repairs and modifications to injection molds for quality control compliance with customers, scheduling, and production control. Worked directly as engineering support with customers on new product development. Created, maintained, and updated PM schedule of production and service injection molds. Reduced monthly expense for repairs and PM's from $18,000.00 to $12,000.00. Established and developed mold design and mold construction standards for consistent interface with molding machines and mold construction quotes. Reduced start up time of new molds from 8 - 10 hours to four hours. Performed small mold repairs to reduce costs during economic downturn. Saved the mold repair budget an additional $3,000.00 to $5,000.00 per month.

Maintained and updated preventative maintenance schedule of production and service injection molds and transfer dies. Managed programs for several customers of new injection mold and transfer die designs, for new construction and engineering changes. Assisted in product development with several customers to achieve best quality product. Supervised three-person internal tool repair facility and several external mold repair shops daily. - Created, maintained, and updated PM schedule of production and service injection molds. Reduced monthly expense for repairs and PM’s by approximately $3,000.00. ·- Participated in several Kaizon events. One event netted a savings of $250,000.00 over a three-year production run at a total cost of $25,000.00.

Coordinated, scheduled, and supervised mold construction through shop with foreman. Trained detailers and CNC programmer to use Auto-CADD software. Supervised detailers and scheduled their work on a daily basis. Downloaded product files from customers to use for injection mold design, separated 3-D surface files to cavity and core surfaces, built parting line surfaces around cavity and cores used in design and CNC programs. Established engineering department to control injection mold designs (all designs were outsourced). Set-up engineering office, computer, drawing plotter, installed software, and developed archive system for drawings and files. This reduced costs from an estimated $80,000.00 each year to under $60,000.00. Utilized experience to design interchangeability into a series of eight molds for a major customer reducing costs by 30%.

I went back to night school while working full time as a mold designer/project manager to get my Plastics Engineering degree and to pursue more challenging professional possibilities.