Automotive Extrusion Specialist
​Joe Havicus

Get Consulting Help Now!

Joe Havicus is an automotive extrusion specialist with significant industry certifications.

With a proven track record in the Tier 1 Automotive Manufacturing, Joe Havicus spearheaded initiatives to improve supplier performance, conducted rigorous audits, and played a critical role in root cause analysis, contributing to the sustained excellence of over 100 automotive component suppliers. With over 25 years Custom Extrusion in the Profile, Fence, Sheet and Recycling plastics industry as a Process Engineer, Plant Manager, New Plant and Equipment Start-Up  Operations Management with some of the largest companies in the industry. His focus has always been on enhancing manufacturing processes and thereby create a substantial impact on the community and industry at large.

​

Experience
Trinity Outfitters LLC - Owner
Feb 2022 - Present
 
Bruss NA - SQE/QE
Oct 2023 - Oct 2024

• Responsible for over 29 Automotive Component Suppliers
• Work with Accounting involving all debit charge backs on defective product
• Review all 8D submissions for SCAR issues
• Perform Supplier Audits and Development Processes
• Insure 0 production interruptions from Supplier Quality issues
• Generate monthly presentations chronicling process improvements on quality issues within Hitachi​ and supplier base to improve profitability
• Assist with root cause analysis on Supplier related issues
• Front line Quality rep to Stellantis
• Processed all OEM complaints and 8D process
• Conducted IATF/VDA 6.3 audits

 
Highlands Diversified - Quality Engineer
September 2020 - February 2022

• Quality Engineer for TBI programs working with new program launches and supplying all PPAP submissions.
• Gauge R&R
• CAP Studies
• Set up and startup of a 30k square foot manufacturing plant from floor to production in less than 90 days.
• Lead on set up of a flatbed dry system paint line produced by Rippert.
• Set up of Spare Parts Inventory for paint line and all Freudenberg Filter system.
• Assist with commission of line start and programming of product parameters utilizing Paint Bells and a 2 booth Primer/Topcoat Solvent Born 2K System coating Class A Exterior Components.
• Vendor Set Up and R&D of Woerwag Paint Products and BASF Paint Products.
• Set up of Lab with all BYK equipment and processes.
• Approval and sign off on Paint vendor and Master Samples.
• PPAP, PSW, PFMEA, Control Plan, Work Instruction creation for BMW program launch.

 
Dajcor Aluminum - Assistant Plant Manager and Quality Manager
Aug 2020 - Sep 2020

• Set up of a New Production Plant that produced Aluminum Extrusions.
• Plant floor layout and material flow.
• Supervision of CNC Machining area.
• Initial set up of the Quality department to include lab equipment.

 
AFG - Quality Engineer
Sep 2019 - Aug 2020

• Lead QE on new program launches at TMMI and TMMK.
• Development of PFMEA and Work Instructions.

 
Dr. Schneider Automotive - Supplier Quality Engineer/Paint Process Engineer
May 2018 - Sep 2019

• Responsible for over 80 Automotive Component Suppliers
• Work with Accounting involving all debit charge backs on defective product
• Review all 8D submissions for SCAR issues
• Perform Supplier Audits and Development Processes
• Insure 0 production interruptions from Supplier Quality issues
• Generate monthly presentations chronicling process improvements on quality issues within Hitachi and supplier base to improve profitability
• Assist with root cause analysis on Supplier related issues
• Process Paint Engineer for a Venjakob wet flatbed paint system.
• Performed R&D with a variety of OEM Paint Suppliers such as Akzo Nobel, Woerwag and Mankiewicz to improve paint process and optimize FTY on painted parts.
• Utilized a spray head bar system with both water born, and solvent born 2K paint, coating interior Class A components.

 
Hitachi Automotive Systems - Senior Technician Supplier Quality (Aluminum Castings) (Electrical Vehicle Components)
Oct 2014 - May 2018

• Responsible for Supplier Quality across several programs and components
• Responsible for PPAP and SREA for new product launches
• Work with CFT and CORE Teams to reduce quality issues and improve production capabilities
• Travel to supplier plant sites in 7 different countries and several U.S. locations to improve Hitachi quality issues
• Generate monthly presentations chronicling process improvements on quality issues within Hitachi and supplier base to improve profitability
• Work with PE, DE and Production to determine root cause of quality issues
• Work with Purchasing to resolve outstanding debits to suppliers and how to recoup those cost from sorting and defective product
• Certified IATF 16949 Auditor
• AIAG Certification in FEMA, PPAP, and APQP
• Mitutoyo MCOMOS C1 Training
• U.K 8 Step Problem Solving completion
• Utilized A3, 5Why, and 4M Methodology to resolve issues
• Kaizen, Kanban, Continuous Improvement, and Lean Manufacturing skills used daily

 
GE - Process Improvement Engineer ABS Sheet Extrusion and Thermoforming
Jan 2013 - 2014

• Assist with daily processing issues with materials and extrusion equipment
• Set up training systems for operators
• Work with purchasing on resourcing vendors for new equipment
• Work with engineering teams to reduce downtime
• Processing ABS sheet
• Led scrap reduction project resulting in a 38% reduction
• Led a material cost out group that saw a million dollars of virgin material reduced annually
• Facilitated the installation of $750,000 of new grinding and material handling equipment and training of maintenance staff

 
Nextlife - Process Engineer Manager of Polyolefin Extrusion Compounding
April 2012 - January 2013

• Assist with daily processing issues with materials and extrusion equipment
• Set up training systems for operators
• Set operating parameters for all materials and extrusion equipment
• Work with corporate on resourcing vendors for new equipment and material streams
• Submitting capital expenditure reports and quoting for building and equipment
• Work with engineering teams to reduce downtime
• Recycling process of HDPE, LDPE, LLDPE, HIPS, EPS, PS, PP
• Through training and equipment changes increased productivity by 60%

 
Play Mart Playgrounds - Project Manager of HDPE Extrusion Line Installation
November 2005 – August 2006

• Generated a Profit and Loss report to inform the company of the financial benefits of purchasing an extrusion line and producing their own product as opposed to buying from outside sources.

• Assisted company in earning state grants to assist in the purchase of new equipment and the hiring of additional personnel.
  

• Coordinated with contractors and the company to ensure effective installation of equipment consisting of Cinn-Milacron 4.5 inch single screw 2 stage vented
  

extruder, Conair vacuum spray tanks, haul off, CNC saw, chiller, granulator gravimetric blending and material handling system.

• Training employees on start-up of all equipment to produce HDPE lumber profiles.
  

 
Innovative Concepts - President/ Owner HDPE/LDPE Composite Decking
2005 – Concluded Business

• Responsible for set up of entire company to include transferring company from North Carolina to eastern Kentucky.
  

• Equipment consisted of 3 custom single screw extruders and all associated equipment to produce a proprietary line of lumber products.
  

• Maintained reports including information on budgeting, accounts receivable/payable, shipping and receiving, and profit and loss margins.
  

• Conducted hiring of all employees, training and maintaining machinery.
• Completed applications for grant proposals. Maintained confidential personnel files on each employee.
  

• Processing LD and PP Cellulose Fiber composite

 
Georgia-Pacific - Line Tech for Polystyrene/Polypropylene Sheet and Thermoforming
2003- 2005

• Supervised team of 6 line operators.
• Responsible for the output and maintenance of a Multi- Layer Thermoforming line that produced Dixie cups and plates.
  

• Maintained machines and plumbing systems.
• Equipment consisted of Black Clawson and Cinn-Milacron single screw extruders ranging in size from 2 inch to 4.5 inch. Brown and Cinn-Milacron Thermoforming
  

and casting units.

• Processing HIPS

 
Infiltrator Systems - Front Line Supervisor of Polyolefin Extrusion Compounding
2002 - 2003

• Direct supervisor of 9 employees.
• Increased production rate by 53% on scheduled shift by training employees on a new process on pelletizing lines consisting of one 8 inch and two 6 inch Merritt-
  

Davis extruders and Beringer pelletizing heads and spin dryers to make compounds of HDPE,LDPE, and PP for our molding plant.

• Decreased tool change over time from 12 hours to 2 hours by informing employees of the benefits gained by using compressed air in the process.
  

• Assisted in the set up and maintenance of machinery for a new product.

 
DJ/NYPRO - Assembly Plant Manager of P&G, Georgia Pacific Products
2000-2002

• Assisted in the set up of the plant, all conveying systems, hiring of employees and establishing company budget.
  

• Completed Government grant proposals, profit and loss analysis and provided job quotes to potential customers.
  

• Served as Project Manager and directly supervised entire workforce of 21 employees.
  

• Acquired all supplies and contractors needed to ensure company productivity.

 
Vinyl Vision - Shift Supervisor/ R&D for Extruded PVC Fencing Profiles
2000

• Worked with contractors on installation of equipment and layout of building during plant expansion, consisting of 7 Cinn-Milacron 55 mm conical twin screw and 92
  

mm parallel twin screw new production lines and CDS auxiliary equipment to produce Rigid PVC fence profiles.

• Trained all company employees on proper operation and maintenance of new machinery.
  

• As only employee assigned to Research and Development, was responsible for the evaluation of new tool sets and making recommendations on how to
  

effectively run them.
 
Mikron Industries - Lead Man of Extruded PVC Window and Door Profiles
1995-2000

• Managed 9 extrusion lines ranging from Cinn-Milacron 55 mm, American Maplan 62 mm and 88 mm, and Krause Mafie 90 mm twin screw extruders and 6
  

operators to ensure that employee and plant safety policies were followed while meeting company standards of top quality Rigid PVC window and door products.

• Led a core TEAM and reduced changeover time from 5 hours to 6 minutes resulting in a 1.5 million dollar savings annually
  

• Served as assistant supervisor and was responsible for various areas of plant operation during the absence of shift supervisor. Areas of responsibility included 26 production lines, 21 operators, shipping, receiving and maintenance of tools and equipment.

• Operated computer controlled material handling systems and all machinery in the Tooling maintenance department.
  

 
Dayton Technologies/ Deceuninck NA - Lead Man of PVC Window and Door Profiles
1989-1995

• Personally supervised 10 extrusion lines and 10 operators.
• Assisted in the set-up of equipment in two major expansions.
• Maintained equipment and helped to drastically reduce change over times.
• Served as assistant supervisor to shift supervisor.
• Worked on a daily basis with product engineering department.

 
EDUCATION
1995

• Associates Degree- Industrial Engineering
• Dayton Technologies/Sinclair Community

 
TECHNICAL EXPERIENCE

• Materials: PVC, HDPE, LLD, LDPE,PP,Styrene,various Composite materials
• Machinery: Cinn-Milacron, Davis-Standard, American-Maplan, Merit-Davis Uniplast, CDS, Gatto, etc.

 
COMPANY CONNECTIONS

• Cinn-Milacron
• American Maplan
• Davis Standard
• Conair
• Kibbechem colorants and additives
• Somerset Recyclables
• AkzoNobel
• Mankiewicz
• Woerwag
• BASF

contact Joe Havicus