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Executive Summary

Innovative, certified professional Project, Technical and Program Manager with extensive international experience in a variety of industries, including automotive manufacturing, construction, appliances and services. Combines vision, technical prowess, and business-management expertise to lead operations, product launches and significantly increase efficiency and quality while decreasing costs.    Fluent in German Language and studying Spanish.

Proven ability to:

  • Manage strategic multi-million dollar capital & tooling projects, timely and within budget
  • Improve product and process designs to increase manufacturing efficiency; reduce complexity and cost
  • Develop and motivate teams to maximize the effectiveness of diverse, lean production systems
  • Identify business opportunities and develop customer relations in multi-cultural operations

    Regardless of my environment, my key transferable skills are:identifying and implementing value-added improvement opportunities, excellent communication and team building skills, and achieving creative results by navigating competitive and uncharted waters.  This includes tactical deployment in distressed, turnaround and start-up situations.

    My objective is to explore opportunities which will utilize my expertise in project and/or program & operations management. My interests lie in manufactured products, automotive, marine, durable goods and business or process consulting.

    Work Experience

    2014Present

    Quality Project Leader - Major/Minor Model Launches

    BMW MANUFACTURING Co. / BERTRANDT

    Responsible to ensure QMT [Purchase Component Quality Engineers] target achievement for vehicle projects during series production face-lifts & minor-model changes. This includes all Driving and controlling QMT target achievement within all vehicle projects.

    Directly support industrialization of purchased components and their integration in the Spartanburg, SC plants for ramp-up to series production. Planning and tracking of process series, capacity and flexibility safeguarding OEM from Tier I and Tier II suppliers. 

    Key role in risk identification and mitigation of any potential supplier related risks to BMW product changes and new model launches. 

    20132013

    Engineering & Quality Manager

    POLYMER GROUP Inc.

    Managed process engineers, technicians, quality manager, quality engineers and laboratory analysts for a 324,000 sq. ft. ~ 210+ employee mfg. site producing over two (2) million lbs. per month of non-woven textile products for the medical, hygiene and industrial industries.

    20102013

    European Programs Manager

    MAGNA INT'L., COSMA DIVISION

    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.
    20042009

    Project Leader - Greenfield Site

    FAURECIA AUTOMOTIVE SEATING

    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.
    20022004

    Advanced Engineering Manager

    INTERTEC SYSTEMS, LLC

    Joint venture of Johnson Controls and INOAC of Japan producing instrument panels and consoles in facilities: United States, Canada and Mexico.

    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.
    20002002

    Entrepreneur, Business Analyst, Engineering Mgt.

    BUSINESS OWNERSHIP & CONSULTING PROJECTS
    • AGM, Inc.-Owner of American 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.
    19972000

    Technical Manager

    LEAR DONNELLY OVERHEAD SYSTEMS, LLC

    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.
    19931997

    Manufacturing Engineering Manager

    ITT CORPORATION - STRUCTURAL and ELECTRICAL SYSTEMS

    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.
    19871993

    Engineering Leader - Stamping & Body Assembly

    MAZDA MOTOR (USA) MANUFACTURING CORPORATION
    • 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].
    19821987

    Industrial Engineer and Cooperative Education Student

    GENERAL MOTORS CORPORATION ~ Body by Fisher

    Participant in a highly touted undergraduate program and assigned to 13 departments.  Published industrial engineering thesis entitled "Improving Press Uptime," reducing changeover times from 7 hours to less than 3 hours through variation reduction, workplace organization and visual controls.

    Education

    19821991

    M.S.,  Manufacturing Management  &  B.S., Industrial Administration

    GMI Engineering & Management Institute

    Kettering University (formerly General Motors Institute & GMI Engineering Mgt. Institute) is a private cooperative education and experiential learning-based university in Flint, Michigan, offering bachelor's [1982-1987] and master's degrees [1989-1991].

    Kettering University undergraduate students are required to complete at least five co-op terms to graduate. Students gain paid work experience in a variety of industries with Kettering's more than 550 corporate partners, including some of the world's top Fortune 500 companies, and graduate with more than two years of professional experience accompanying their degree.

    20102010

    Project Management Professional (PMP)®

    Project Management Institute

    The Project Management Professional (PMP)® is the most important industry-recognized certification for project managers.

    You can find PMPs leading projects in nearly every country and, unlike other certifications that focus on a particular geography or domain, the PMP® is truly global.  As a PMP, you can work in virtually any industry, with any methodology and in any location.

    20092010

    Lean Six Sigma Blackbelt Certification [Mfg. & Service]

    Greenville Technical College

    The curriculum includes all the key tools and skills needed to get fast, sustainable project results. Action learning approach incorporates simulations, examples, team exercises, and case studies taken from real world problems faced by real companies. Learn Mionitab through hands-on exercises. To ensure competency and understanding, black belts participants are expected to demonstrate abilities through in-class evaluations, exercises, exams teach backs and a completed off-site project.

    Highlights include DMAIC, project definition, control charts, capability analysis, value stream and process mapping, measurement system analysis, regression, hypothesis testing, ANOVA, DOE, FMEA, mistake prodding, cycle time reduction, analytical batch sizing, 5S, pull systems, TPM, quick changeover, process flow and balancing, and much more.

    20092009

    Essentials & Mastering Project Management

    Villanova University

    Project Plan Development:

    • Introduction to Project Plan Development
    • Collect Requirements
    • Create Work Breakdown Structure
    • Plan Quality
    • Develop Schedule
    • Estimate Costs
    • Plan Communications
    • Identify Risks
    • Plan Procurement
    • Scope Baseline
    • The Project Management Plan

    People-Based Project Management:

    • Myers-Briggs Type Indicator
    • Scoring the Instrument and Interpreting the Results
    • The Dimensions
    • The Sixteen Types and the Temperaments
    • Recognizing the Type in Others
    • Acknowledging the Differences
    • Communication and Personality Type
    • Personality in Teams
    • Creating a Project Management Culture
    • Project Management Maturity
    • The ROI of Project Management
    • Introduction to Maximizing Influence
    • Planning and Initiation
    • Project Execution
    • Metrics and Resolution

    Project Performance Management:

    • Direct and Manage Project Execution
    • Scope, Schedule, and Cost Monitoring
    • Earned Value Measurement Methods
    • Variances and Indexes
    • Forecasting
    • Recovery Metrics and Responses

    Practical Project Management:

    • Emotional Intelligence for Project Managers
    • Identifying and Understanding Emotions
    • Understanding the Project Environment
    • How Healthy is Your Team?
    • Corporate Trust
    • Stress Management
    • Motivating Project Teams
    • Motivational Strategies and Tactics
    • Developing a Coherent Plan
    • Navigating a Diverse Landscape
    • Managing Diversity and Inclusion
    • Gender and Project Management
    • The Global Landscape
    19822017

    Professional Engineering Societies & Affiliations:

    Member,  Project Management Institute [PMI]

    Senior Member,  Institute of Industrial Engineers [IIE]

    Senior Member,  Society of Manufacturing Engineers [SME]

    Product Experience

    International Liaison Activities

    Germany:

    München,  BMW FIZ  R & D Center

    Dingolfing, BMW Assembly Plant

    München, BMW Assembly Plant

    Leipzig, BMW Assembly Plant

    Bad Abbach Plant, Faurecia Seating

    Geiselhöring Plant, Faurecia Structures

    München, Faurecia Service Office

    Neuburg Plant, Faurecia

    Leipzig, Faurecia

     

    Japan:

    Hiroshima Ujina 1, Mazda Corp

    Toyama, Nachi Robotics

    Canada & Mexico:

    St. Marys, Ontario, Canada

    Ramos Arizpe, Mexico

    Netherlands:

    Sittard, Faurecia Seating

    United States:

    Spartanburg SC, BMW Plant

    Troy MI, Faurecia Headquarters

    Fountain Inn, SC Faurecia

    Auburn Hills MI, Faurecia

    Sterling Heights, MI, Faurecia

    Clyde OH, Wollin & Whirlpool

    Bardstown KY, Intertec Systems

    Rochester & Elsie MI, ITT

    Flat Rock MI, Mazda Assembly Plant

    Kalamazoo MI, General Motors

    Project & Portfolio Management

    Industrialization examples of major scale projects.  Proficient with multiple Program Management systems, Certified PMP in PMI methods, in addition to diversified corporations such as BMW, Mercedes, MAGNA, Faurecia and Johnson Controls.

    Major Vehicle Launches for OEM

    Credentials  &  Recognition

    Evidence of credentials, licenses, training courses and examples of employer recognition.

    Résumé  Dowload

    Competencies  and  Certifications

    Certifications, Training Seminars or courses:

    Verband der Automobilindustrie 6.1 Certification [European Automotive Stds.]

    Dale Carnegie Course™ - Oral Communications

    Franklin-Covey ™ Time Management Training

    MP2 - Professional Maintenance & Materials Management

    The George Group - Lean 6 σ Blackbelt Certification

    Nachi 8608 Robot Operation / Programming

    Komatsu Press Mechanical Training

    North American Crane Bureau Rigging Safety

    ITT Employee Involvement Recognition

    SkillPath™ - Negativity in the Workplace

    SkillPath™ - Coaching and Teambuilding Training

    CareerTrack - Team Leader Training

    CMI - Bill of Material / Routing

    GZAHazardous Materials / DOT Training

    G.M.- Quick Change Over Workshop (PICOs) Award

    Ford Motor - Witness Computer Simulation Basic / Advanced

    Shainin Consultants, Inc. ™  - Statistical Engineering Seminarä

    Allen Bradley - Electrical PLC Basic Course

    MRW, Inc. - Managing Relationships at Work

    Mazda - Time Study and Work Rating Certification

    Technology / Engineering / Leadership

    Lean Thinking / Manufacturing

    Manpower Modeling

    Resource Allocation Planning

    Innovative Engineering Change Processes

    Kaizen / Continuous Improvement

    Value-Stream Mapping

    JIT - Just - In - Time Shipping / Manufacturing

    KanBan - Pull Scheduling Systems

    Diversified Industrial Engineering Experience

    TPM Total Productive Maintenance

    SPC - Statistical Process Control

    Process Flow Documentation PFLOW

    Failure Mode Effect Analysis DFMEA, and PFMEA

    Pokeyoke Evaluation and Implementation

    Green Field Plant Construction

    Closed-Loop Systems

    BOM Bill of Material and Routings

    Work Measurement / Work Flow Methods Analysis

    Witness Computer Process Modeling

    Management Systems and Administration

    Strategic Business Planning

    TS-16949

    Plant Safety & Ergonomic Evaluation & CoordinationPurchasing - Materials, Heavy & Light Equipment

    Tooling Budgeting and Procurement

    Visual Management

    OSHA, NFPA, HazMat, DOT, BOCA, etc.

    Regulatory Compliance Auditing

    ISO 9000/ 9001 Implementation

    Work Place Relations Management

    Business Performance Measurement Systems

    Progressive Plant Maintenance Programs

    Shainin Statistical Engineering Processes

    Kepner Tregoe™ Analytical Troubleshooting

    People / Work Relations / Training

    360° Leadership Feedback Manager

    Continuous Improvement, Production Systems

    Time Management Trainer

    Self Directed Work Team Creation

    Cross-functional Team Building Trainer

    Employee Recruitment & Motivation

    Negativity Management

    Staff Mentoring and Development

    Career ladder Programs

    Change Management

    Worker - Robot Automation Integration

    Cooperative Education Programs & Thesis Advisor

    Process  Experience  Examples

    Hot Stamping [Hot Forming or Press Hardening]

    Conventional Stamping & Blanking

    Laser Trimming

    Assembly and Weld Cell Automation

    Progressive Form Dies

    Spunbond Non-woven Hygiene & Healthcare

    Melt Blown Non-woven Textiles

    Interior Components & Soft Trim manufacturing

    Electro Mechanical Structural Systems - Automotive

    Washing Machines / Dishwashers

    Composites and Substrates

    Noise/Vibration Insulators

    Sound Signature Analysis

    Rotational Powder Casting

    Manual and Automated Assembly

    Sheet Metal Fabrication / Stamping

    Material Handling / Assembly - Robotic

    Powder Paint Coating

    CNC Fabric Cutting

    Vacuum Forming

    Water Jet Cutting - Robotic

    RF Welding

    Substrate Laminating

    Fabric Sewing

    Robotic Adhesive Application

    Resistance Welding

    Heat Staking

    Riveting

    Spin Staking - Ferrous

    Spin Welding - Plastics

    Ultrasonic Welding

    TIG / MIG Manual & Auto Welding

    Plastic Injection Molding

    Fine Blanking & GripFLOW

    Sheet Metal Stamping – Heavy guage

    Large Appearance Panel Stamping

    Roll Forming - Steel

    Laser Marking / Etching

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