Artur Z

Process Engineer with 20 years of robust manufacturing experience specializing in process optimization, waste reduction, and driving shop-floor efficiency. Proven track record of lifting performance across Safety, Quality, Delivery, and Cost metrics within fast-paced industrial environments. Expert in structured problem-solving, Root Cause Analysis (RCA), and deploying formal Lean / Continuous Improvement tools including Six Sigma, Kaizen, and 5S to eliminate operational waste and optimize cycle times.

Methodical and data-driven professional.

Process Engineer - WHS Plastics Brierley Hill Ltd - Brierley Hill

(2023-12)

• Supported car interior and exterior components
• Process and tools validation
• Utilized formal Lean and Continuous Improvement techniques to stabilize, validate, and optimize 250 (Formaplex) Aston Martin tooling programs transferred to production lines.
• Enforced strict workplace safety protocols, tracking equipment conditions and implementing preventative countermeasures to improve overall line ergonomics and operator safety.
• Collaborated closely with Tool Room and Quality to identify root causes of processing, implementing corrective actions.
• Regularly reviewing and updating PFMEA, Process Flows

Process Engineer - Magna Exteriors (BANBURY UK) LIMITED - Banbury, UK

(2021-05 - 2023-06)

• Supported car exterior, moulding production for Germany and UK including BMW mini, Jaguar.
• Optimized NPI cycle time delivering a documented 300k+ cost saving in the first year through scientific moulding.
• New BMW mini Project validated on site 18 exterior tools. 600-3800T Kraus and Demags
• Conducted international tool trials at tier-1 toolmakers in the UK and Portugal (simoldes) verifying tool specification, gating, and cooling layouts prior to delivery
• Applied structured Root Cause Analysis to identify and correct complex tooling faults, preventing recurring failures and improving process
• Collaborated with product design team and quality engineering groups on material selection, design feasibility and product, process control of new parts.

Contract work - Mold Solution Consulting AG - Based at Sky-wing precision Doungan Shenzen China

(2020-11 - 2021-03)

• Validated 5 Project and trial requested prior purchase of medical (Wundspreizerfor PEEK)
• Attended toolmakers, checked tools specification, trailed and tested equipment before shipment, Used scientific moulding approach and documented.

Senior Process Technical - China Tool Automotive Systems - Shenzen, China

(2019-11 - 2020-10)

Managed and lead group of trial team technicians, multiple moulding programs in house and customer toolmaker based. Performing run-off of new products. Ensured injection moulded part quality meets engineering specifications.

Provided feedback for corrective actions to tooling engineering, moulding and material suppliers. Recommended mould design changes for improving productivity and quality. Established manufacturing processes for new tooling.

Troubleshot processing issues, identified root causes, instituted corrective actions, and standardized processes. Conducted mould validation prior to transfer to production.

• Supported car interior, moulding production for Japanese and American OEMs including Ford, Mazda, Tesla, Nissan, Faurecia and Bentley
• Implemented lean manufacturing and Six Sigma to improve cycle time and production processes.
• Developed and conducted training with supplier engineers and trial team to utilize new materials processing techniques.
• Collaborated with supply management, product design and quality engineering groups

Senior Process Engineer and Supervisor - eGreen - Northampton, UK

(2018-03 - 2019-09)

Restarted and validated production lines after plant relocation. Improved cycle time and production efficiency. Worked with tooling technicians and mould makers to resolve part issues. Performed programming and PLC adjustment to Sepro and Wittman robots. Completed research of new biodegradable polymers (PLA, biome HT, POM) for future products. Troubleshot by locating and rectifying faults on equipment.

• Validated and restarted all production lines, equipment at new premises.
• Collaborated with tool room and tool makers to bring cavitation back to 100%.
• Experienced in using various polymers including polypropylene, polystyrene, polycarbonate switching to PET RPET and dryton.
• Optimized machinery processes for Krauss Maffeir, multi cavity tools and hot runner systems to switch for RPET and other Bio
• Implemented lean continuous improvement techniques including Kaizen, near miss and 5 Sigma.

Setting and Automation Technician - RPC Containers Ltd. - Blackburn, UK

(2016-12 - 2018-02)

Supported Mars project containing 4 BMB 400T-800T and Ilsemann machines in mould labelling (IML) automation robots. Conducted daily quality monitoring using Mitutoyo to coordinate measuring and colour density. Monitored manufacturing to achieve KPI standards.

• Reduced wastage by programming and improving Mevisco, quality camera software.
• Optimized IML robots to speed up processes.
• Achieved overall m/c cost efficiency to target.
• Tracked and optimized cycle times.

Process Technician - Phillips Avent Ltd. - Suffolk, UK

(2011-11 - 2016-11)

Performed tooling changeover and equipment calibration. Identified and improved engineering processes to reduce wastage. Diagnosed and corrected basic electrical issues including sensors, PLC and motors. Worked with multiple value streams including Demag and Nissei 50T – 500T, three axis multi Sepro robots and two twin shot turntable Demags, containing 15 m/c and 10 blow mouldings. Conducted first line maintenance and assessed breakdowns. Trained new technicians.

• Supported Kanban design.
• Optimized process quality by improving existing software and weight management tools leading to faster production speed using scientific methods including Pro-op software and weight management RJG standard.
• Experienced with polymer production of various grades including drayton, polypropylene, polystyrene and Pes
• Provided solutions for value stream problems in executive meetings.

Trainee Setter, Tool Setter and supervisor - Plastico Ltd. - London, UK

(2007-03 - 2011-11)

Led production staff to follow the devised production plans. Programmed various machines and robot parameters for tool setting. Conducted daily quality monitoring, process control and ensure parts met customer specifications. Completed regular maintenance of machines and equipment.

• In-process optimization of various moulding machines including Krass Maffei, Bilion, Boy 50T – 350T, multi cavity tools and hot runner systems. Cutlery and glass products
• Supported projects with new equipment and raping machine conveyers.

Bachelor - Management and Marketing - University of Management, Częstochowa, Poland (2002 - 2005)

Maintenance Technician NVQ-3 - S. Staszic Group of Vocational School, Częstochowa, Poland (1997)