MAGNA INT'L., COSMA DIVISION
2010 - 2012
European Programs Manager
Managed Sales, Pricing, P&L, Delivery, Automation & Capital, Quality/Regulatory Compliance and Program Management for Mercedes, BMW, Volkswagen manufacturers in Knoxville, Tennessee, United States.
- Successful annual profitability improvements of USD$1.1 million/year through customer management, product & material pricing negotiations and creative cost reduction activities.
- Directed multiple projects, each to USD$4.3 million, mitigated new technology risks for innovative structural component hot stamping, laser trimming and assembly operations.
- New product estimating and formal quoting led to awards of Mercedes and BMW program awards.
- Daimler and BMW supplier B-2-B systems, inc. Program Launch, Logistics and Quality portals.
VDA [Verband der Automobilindustrie] 6.1 Process Auditor Certification.
FAURECIA AUTOMOTIVE SEATING
2004 - 2009
Directed the activities of a cross-functional team in establishing a new mfg. site for BMW seating systems. Scope also included product, processes, layout, capital to launch BMW X-5, X-6 and Hybrid vehicles from design in Munich, Germany to complete industrialization in South Carolina, United States.
- Re-designed and retrofitted over 53 implemented designs to service a customer base with over 7,000+ product variations representing over USD$ 220 million annually.
- Built credibility & trust through open, direct communication and presentations as "principle liaison" between various internal/external supplier & BMW customer groups in Europe and North America. Worked in multiple facilities and design centers for BMW and Faurecia Munich, inc. Neuburg, Leipzig, Bad Abbach and Munich as expatriate living in Germany.
- Managed USD$ 5.1 million capital budget and technical specifications to acquire new processes and facility, e.g. production lines, shipping systems on schedule and budget while delivering exceptional initial quality on-time.
- Attained Faurecia Excellence System product & process scores of 98% and 97%, in addition to 98% ergonomic score.
- Accelerated output post start-up by increasing daily volume from 460 car sets per day to up to 530 car sets per day.
- Led BMW simultaneous engineering activities for changes from development, quoting through implementation for product feature enhancements and cost reduction activities.
INTERTEC SYSTEMS, LLC
2002 - 2004
Joint venture of Johnson Controls and INOAC of Japan producing instrument panels and consoles in facilities: United States, Canada and Mexico.
Advanced Engineering Manager
Managed eight major programs for General Motors, Toyota, Ford, and Honda adding $52 million in sales.
- Introduced innovative capital justification systems, cost tracking, equipment design and specification with 0 ppm (part/million) and 100% efficiency targets 30 days post launch.
- Managed USD $27 million capital budget and generated over $8 million in savings.
- Added innovative $5.1 million powder casting operation and new building to Ontario facility, in addition to paint systems, molding presses, and state-of-art laser perforating operations that aid passive restraint air bag deployments.
- Mentored and influenced engineering team to increase program delivery despite a 20% reduction in staff.
- Developed a creative manufacturing layout that optimized material flow and production control and reduced floor space of one program from 27,000 sq. ft to 9,800 sq. ft.
BUSINESS OWNERSHIP & CONSULTING PROJECTS
2000 - 2002
- AGM, Inc.-Owner of Granite & Marble Import Business. Established business plan, accounting systems, purchasing, marketing plans, logistics and sales of commercial and residential projects in Orlando, Florida.
- PDP, Inc., Angell Construction, Inc. - Business Consultant for $10 million commercial, residential and construction company in Tampa, FL. Identified and implemented $565,938 savings, with a 3:1 return on investment through various operational, organizational and financial re-engineering activities.
- Wollin Products - Engineering Supervisor Assignment for $70 million plastics molding company producing a million parts per day to Whirlpool washing & drier industry in Clyde, OH. Created a "factory of the future", increasing plant efficiencies and providing optimal ergonomics and product flow, resulting in cost savings of $250,000/year.
LEAR DONNELLY OVERHEAD SYSTEMS, LLC
1997 - 2000
Directed the activities of 42 professionals and technical personnel for joint venture producing over 36,000 automotive electro-mechanical sun visors and composite headliners per day in Marlette, MI.
- Conceptualized and implemented additional business, increasing sales by $14 million through cost justifying, designing plant layout, pull scheduling and introducing new flexible forming technology.
- Managed 27 major and minor product launches in three years, including supporting foreign launches with cost estimating/tooling. Conducting Kaizen COMPASS activities to improve efficiency and create enough floor space to accommodate growth. Complete responsibility for a $3.9 million capital budget.
- Restructured maintenance to a visual TPM planned maintenance system resulting in decreased machine failures, faster repairs, and consistently achieving 95% equipment uptime with expenses below budget.
ITT CORPORATION - STRUCTURAL and ELECTRICAL SYSTEMS
1993 - 1997
Manufacturing Engineering Manager
Led all engineering activities for an 800-employee business producing more than 96,000 power and manual seats each month in Elsie, MI. Other products included motorized gears, torsion bars, etc.
- Coordinated seven new program introductions with complete project management responsibility for $2.8 million annual capital budget for innovative testing, paint, welding, tooling and precision stampings.
- Managed staff utilizing value analysis and computer simulation to switch two assembly lines into flexible work cells, resulting in $990,000/year savings.
- Focused kaizen activities for management peer team to: reduce work process inventory from $763,000 to $311,000 (60%); inventory from $4.9 million to $3.4 million (30% reduction); and production output was increased from 176 to 238 power seats built per employee.
- Reorganized personnel with annual savings of $740,000/year on sales of $120 million. Acting Plant Manager as required and installed process fail-safes, reducing customer returns from 1,263 to 69 PPM, considered "world class," and received General Motor's Supplier Improvement Award.
MAZDA MOTOR (USA) MANUFACTURING CORPORATION
1987 - 1993
Engineering Leader - Stamping & Body Assembly
- Promoted from Industrial & Facilities Specialist in first Mazda plant in Detroit, MI Exceeded 1,000 Ford Probe and Mazda MX-6 automobiles per day.
- Coordinated 1992, 1994 new model for facilities, equipment, and directly managed tooling tryout, including overseeing pilot, quality and productivity of 427 new dies designed and built in Japan. Combined kaizen skills and press/automation knowledge to lead team in Die Change Challenge competition over four years, achieving internationally acclaimed Overall Winner '90 and Best in North America '92. [ref.: Automotive Industries Magazine].
GENERAL MOTORS CORPORATION
1982 - 1987
Industrial Engineer and cooperative education student in highly touted undergraduate program and assigned to 13 departments. Published thesis entitled "Improving Press Uptime," reducing changeover times from 7 hours to less than 3 hours through variation reduction, workplace organization and visual controls.