Chris Knaffle

EducationBachelor of Science: Welding Engineering Technology May 2002Ferris State University; Big Rapids, MI

Graduated with High Distinction Honors

Associate in Applied Science: Welding Technology May 2000Ferris State University; Big Rapids, MI

Graduated with Highest Distinction Honors

Additional Training Classes Motoman Advanced Robot Programming; multiple locations, 2011 - 2014 SKS Welding Machines Programming and Operation; Michigan Arc Products, Detroit, MI; 2012 Fanuc Robotics / Lincoln Electric MIG and Tandem MIG training; Lincoln Electric, Cleveland, OH; 2010 Lean Champion Training; Michigan Manufacturing Technology Center, Plymouth, MI; 2008 Fanuc Robotics Spot Tool Plus Programming Class; Fanuc Robotics, Auburn Hills, MI; 2007 Certified Welding Inspector (CWI) #07040941; American Welding Society; 2007 Motoman Basic Robotic Programming Class; Motoman, West Carrollton, OH, 2006 ABB Basic Robotic Programming Class; ABB, Auburn Hills, MI; 2004 Volvo Quality Improvement Tools; Volvo Construction Equipment, Skyland, NC; 2003 Fanuc Robotics Basic Robotic Programming Class; Genesis Systems Corporation, Davenport, IA; 2002 Fanuc Robotics Advanced Robotic Programming Class; Genesis Systems Corporation, Davenport, IA; 2002 Introduction to Pro/Engineer; PTC Precision Learning Partner, Troy, MI; 2002

Work Experience General Experience Overview: I have over 20 years experience in welding, production, and fabrication working with a

large variety of product types and materials, from light-gauge sheet-metal and tubing to heavy plate and castings in manual and automated applications including steel, stainless steel, and aluminum. I have been an integral part of many new plant start-ups, new product launches, and major welding improvement efforts.

General Robotics: experience working with the following brands of robots in MIG welding, resistance welding, sealant/glue application, rivet application, and material handling applications: Fanuc, Motoman, ABB, and Panasonic; very proficient with Fanuc and Motoman

Application Specific Robot Programming: all welding-related setup and programming for resistance, MIG, and tandem MIG welding; weld path development; touch sensing; seam tracking; coordinated motion welding with multiple auxiliary axes; simultaneous (multiple robot) coordinated motion, multiple tools; multiple-pass welding; automated error-recovery; part identification and verification; auxiliary axes control; sealant path development; spot weld and rivet placement

Welding Processes: extensive hand-on experience with all common welding processes; certified welder in several processes and materials; specializing in MIG / FCAW and resistance welding in manual, automated, or semi-automatic applications; very familiar with Miller, Lincoln, Fronius, and SKS welding equipment and have worked with many others.

WPS / PQR Development and Qualification: developing and qualifying welding processes (and welders) to code / customer requirements; performing required destructive testing and evaluation; materials evaluation process development (destructive test and macro etch)

Leadership for New Equipment Builds: training and leading robotic simulation specialists, robot programmers, and weld engineers in all aspects of welding and program development from machine concepts to optimized production

Certified Welding Inspector Activities: inspecting weld quality per customer requirements; training proper welding knowledge and inspection techniques across multiple departments; conducting tests to certify welders and automated welding processes; performing destructive testing including macro etch, guided bend test, and destructive tests

Training Activities: conducting training classes (both classroom and hands-on) on a large variety of subjects related to welding processes; creating training material and presentations; creating floor-level documents for daily production support; teaching welding, from basics to advanced techniques and processes; teaching robot programming

New Product Launch: specifying equipment related to welding systems prior to equipment build; calculating robot and welding cycle times; assisting in APQP development; giving technical advice about equipment design specific to electrical controls, welding fixture design, weld cell design and welding equipment design; technical project management; building prototype parts; setup support of welding equipment; equipment buy-off; floor support during launch and de-bug stages; training operators and maintenance personnel proper machine functions and programming; developing production-support paperwork

Improving Existing Processes: overall optimization of all parameters related to welding to yield the highest quality welds; decreasing weld time and cell cycle time; increasing travel speeds and deposition rates; reducing spatter and expulsion; reducing rework; redesign of fixtures for process improvements

Lean Manufacturing Activities: experience working in a lean environment; participating in Kaizen events; trained as a lean champion and able to independently lead Kaizen events

Chris Knaffle / welding engineer resume Page 1 of 2

phone: 734-223-3580email: cknaffle@reautomated.com

Specific Cost-Reduction Activities: coordinating complete cost-reduction activities from start to finish: identifying opportunities, calculating expenses and ROI, obtaining financial authorization, developing timeline for implementation of change, conducting or assisting in implementation of changes, training, follow-up to verifying savings

Fixtures: experience designing and redesigning fixtures for parts ranging from very small to 25+ tons; adjusting for proper part fit and geometry, weld joint fitup, and dimensional requirements; tuning to meet CPK requirements; implementing / improving Poke-Yoke systems; selecting optimum materials to survive in a welding environment; improving designs to: match GD&T schemes, minimize distortion and part movement, allow optimum weld gun access and angle, increased operator usability, quicker load / unload times; optimize pneumatic systems to reduce cycle time

Establishing Ongoing Quality Control: creating troubleshooting guides to assist skilled trades in diagnosing equipment problems; creating procedures that define allowable range of adjustments; working with management to hold renegades responsible for unauthorized changes

Supervisory Experience: leading a team of up to 23 employees to commission previously-used equipment from setup and first power-on to production stable; responsible for all aspects of weld validation (destructive teardown) in the resistance welding department including scheduling and managing employees; temporary (3 months) maintenance department manager; leading a team of robot programmers to program new weld equipment for an entire new facility

Researching and Implementing New Technology: networking with suppliers, manufacturers, and peers to identify new technology that will lead to cost reductions and quality improvements; hands-on scientific evaluation of new technology; implementation of new technology to improve inferior processes

Weld Consumable Management: specifying all consumables to be used; reorganizing and condensing inventory of weld consumables and supplies (1000+ part numbers); developing stock level and reorder system; ordering all required production supplies on time within budget

Other Welding, Fabrication, and Machining Experience: repairing / reworking machined weldments and castings; conducting welder tests / specifying welders to be hired; programming CNC plasma / flame cutting machine; programming CNC press brake; designing and fabricating custom weldments for a large variety of applications; competent with most common machine-shop tools (mill, lathe, grinder, drill press, etc.)

Computer Experience working with computers and creating large reports, spreadsheets, presentations, and technical drawings to be

used internally and presented to customers Proficient working with Microsoft Word, Excel, Powerpoint, and Outlook; AutoCAD, Struers Welding Expert Accustomed to managing 100+ emails a day

Work HistoryApril 2011 – present R&E Automated17500 23 Mile Rd, Macomb, MI 48044Senior Welding Engineer / Robot Programmer / CWI / Project Manager / Jobsite Supervisor

November 2008 – April 2011 Fusion Welding Solutions47686 Van Dyke, Shelby Township, MI 48317Lead Welding Engineer / Robot Programmer / CWI

November 2003 – November 2008 SKD Automotive260 Gaige St., Jonesville, MI 49250Welding Engineer / CWI

March 2002 – November 2003 K&M Machine-Fabricating, Inc.P.O. Box 218, 20745 M60 East, Cassopolis, MI 49031Welding Engineer

May 2001 – August 2001 Joy Global Corporation / P&H Mining4400 W. Nation Avenue, Milwaukee, Wisconsin 53214Welding Engineer Intern

April 1994 – May 2002 Johnston Metalwork11622-C North Straits Hwy, Cheboygan, MI 49721Welder, Fabricator, General Laborer, Team Leader

September 2000 – April 2002 Ferris State UniversityCollege of Technology, 1009 Campus Drive, Big Rapids, MI 49307Welding Laboratory Tutor

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