James Bohley


An Engineering Project Manager with extensive experience in the automotive industry. Expertise in product development from concept to launch. Exceptional skills in product design. Very knowledgeable of product tooling, equipment and fixtures. Proven leadership with complex technical projects which achieved targeted objectives in timing, cost, investment, performance, and customer expectations. Extensive experience with international business projects.. Excellent communication skills, both oral and written. Thorough follow-through skills. A solid team player who motivates and strives to achieve project targeted results.

Work History

Work History
Feb 1995 - Sep 2009

General Motors
Lead Application Engineer, July 2008 - September 2009

Chaired a Product Development Team of approximately 20 cross-functional team members responsible for all aspects of design, engineering, and launch of instrument panel and floor console of a critical program. Designed complex injection-molded plastic, stamped and welded steel, and die-cast metal parts, leading teams of up to 8 computer aided designers.

  • Managed multi-million dollar product program with critical contributors in the US, Canada, and Australia, ensuring effective communication and collaboration.

  • Coordinated the team that successfully transferred several hundred molds, assembly tools, and fixtures to a new supplier, achieving production volumes and quality in the required four week time frame. Part inventories were maintained, plant downtime was avoided, and $3-5 million of revenue per day was preserved.

  • Tracked and expedited closure of open issues with the international team, implementing needed changes as quickly as possible, improving quality, assembly, and eliminating rework costs of up to $100,000 per year.

  • Minimized cost and complexity of tooling changes by creating solutions that were compatible with the existing tool design.

  • Achieved world-class fit and finish by collaborating with subject matter experts to define and document Geometric Dimensioning & Tolerancing as appropriate.

  • Communicated effectively in formal and informal settings to all levels of the organization in order to ensure product status and challenges were understood and any needed assistance was obtained.

  • Developed, tracked, and implemented complex design and engineering changes costing several hundred thousand dollars, which improved quality and impacted multiple large tools.

Apr 2002 - Jul 2008

General Motors
Lead Project Engineer, April 2002 - July 2008

Led design, development, and launch of multiple steering wheel and driver airbag programs. Created requirements documentation and test plans. Rigorously reviewed and evaluated change requests from suppliers for compliance to program scope. Authorized payment of engineering and development funding of up to $1 million to suppliers upon completion of work.

  • Provided technical expertise to all phases of acquisition and sourcing activities as the primary engineering contact, which assured the successful execution of $4-5 million per year programs.

  • Led development of two new steering wheel and driver airbag families from design sketches to product launch by collaborating with creative designers and program managers to incorporate up-to-date features and design elements while maintaining the required levels of commonality with existing products and meeting all performance requirements and financial targets.

  • Mentored others in the organization with process, technical, and human resource issues in recognition of technical expertise and effective coaching skills.

  • Recognized reputation for reacting to emerging issues immediately, quickly understanding the issue, creating a containment action, and initiating design activities to permanently eliminate the issue.

Apr 1998 - Apr 2002

General Motors
Senior Project Engineer, April 1998 - April 2002

Designed and released steering wheels and driver airbags for multiple programs. Created and leveraged Design Failure Mode Effects Analysis (DFMEAs) to guide designs and test plans at the component and subsystem level.

  • Ensured compliance with internal and governmental regulations by collaborating with crashworthiness engineers. Leveraged advanced simulation and analysis tools to develop needed design changes and add new design features to increase customer satisfaction..

  • Reduced product cost 5 - 10% by developing and implementing product and process improvements.

  • Led development and launch of new-technology airbag inflators for cost reductions of up to $5 per vehicle with no impact to downstream users or customers.

May 1997 - Apr 1998

General Motors
Senior Contact Engineer, May 1997 - April 1998

Performed current product design/release engineering for various interior components. Interfaced with suppliers, assembly plants, and program personnel to identify and resolve cost, quality, warranty, and production issues.

Feb 1995 - May 1997

General Motors
Project Engineer

Collaborated with a design-responsible supplier and internal engineering resources to ensure vehicle-level requirements were met for a low-volume specialty program.

  • Resolved a significant design issue in a critical vehicle component using finite element analysis.

  • Ensured compliance with safety standards, cooperating with multiple other functional teams by implementing process and design changes late in the program.

Jun 1992 - Feb 1995

Troy Design, Inc.
Project Engineer March 1993 - February 1995

Contracted to Audio Systems Engineering, Delco Electronics Corp. Designed and released injection-molded speaker housings, providing direction to two computer-aided designers.

Project Engineer June 1992 - March 1993

Contracted to Specialty Vehicles Engineering, General Motors. Provided engineering support for launch of a low-volume specialty vehicle.