Integrate design, manufacturing and managerial experience with a motivated team, sharing a common vision, to develop products and processes that exceed corporate standards and objectives and customer expectations resulting in lasting relationships that ensure future success.
DIRECTOR OF ENGINEERING
Electric Automotive Industry
Lean Six Sigma / Advanced Product Quality Planning / Toyota Production System
SUMMARY
Visionary manager of multiple disciplinary top-level lean teams in start-up organizations.
Earned recognition as being subject matter expert in areas associated to engineering and cross-functional activities between teams.
Exceptional in reallocation of unused funding that enabled subsequent functions to initiate sooner, increasing fidelity in final product.
Produced clear, unified vision of individual contribution to achieve significant cost avoidance to entire corporation.
Provided policy/procedure structure within organization to generate shared use of best practices.
Superb in creating working environment to encourage team and individual creativity.
Strengths include:
Product Life Cycle Management
Continuous Improvement Engineering
Emerging Manufacturing Technologies
Start-Up Engineering Departments
Cross-Departmental Communications
Department Of Energy Documentation
Corporate Engineering Representative
Shared Best Practices & Lessons Learned
Lean Processing-Environmental Friendliness
4 Patents Awarded:
1) Adjustable three-piece hydroformed sport bar
2) Apparatus for transferring impact energy from a tire and wheel assembly
3) Door adjusting bumper providing show surface alignment
4) Brake cooling system
CAREER PROGRESSION & SELECT ACCOMPLISHMENTS
Director of Engineering
Tesla Motors, Inc. (OEM for Automotive – Electric Vehicles) Auburn Hills, MI / 2006 to present
• Hired as 2nd employee of start-up organization; recruit/develop/supervise 12 Engineering Managers and Project Engineers.
• Leadership of Design, Engineering, and Manufacturing, implementing Lean Six Sigma and Toyota Production System principles.
• Develop and manage budget of $30M+.
• Work closely with supply chain, marketing, quality and manufacturing to develop request for proposals, request for quotes and statement of work documentation.
• Organize/chair weekly design reviews for all interfacing disciplines (marketing, quality, supply chain, senior management, etc.) managing all open issues to completion.
• Build strong relationships with suppliers and conduct major focus on recyclable/sustainable materials being developed by emerging manufacturing technologies.
Select Accomplishments:
• Recruited/assembled lean team of highly motivated individuals that were able to exceed all senior managerial expectations.
• Authored product engineering responses to Department of Energy inquiries for 2 separate articles, Title 17 and Title 136, successfully passing technical due diligence phases of governmental loan program.
• Developed best practices standards, documented and released protocols to organization for product release for production; received high accolades from president of potential partnership.
• Integrated Lean Six Sigma and Toyota Production System processes to provide input into state-of-the-art manufacturing facility for lean processing and environmental friendliness (initiated with ‘Greenfield’ sites, then transferred to ‘Brownfield’).
• Managed cradle-to-grave Advanced Product Quality Planning (APQP); provided valuable input/guidance to lean team from informational technology perspective to minimize downtime/disruption of remote location.
Senior Product Engineer
Intertec Systems, Inc. – Johnson Controls – INOAC Joint Venture (Tier One Supplier-Automotive Interiors) Troy, MI / 2005 - 2006
• Provide design, engineering, manufacturing and managerial experience to lead 3 Toyota interior programs.
• Manage over (140) tools on 3 continents – Japan, United States and China.
• Develop/maintained design validation plan and reports (DVP&R), design failure mode effect analyses (DFMEA), engineering and manufacturing bill-of-materials (BOM), and engineering change requests (ECR/ECO).
• Work closely with quality personnel to establish robust planning and metrics to ensure successful project execution.
• Lead engineering to provide manufacturing feasibility input to customer; representative in senior level customer meetings.
• Oversee highly skilled engineering team; key customer liaison- extensive international travel to Asia.
Select Accomplishments:
• Assumed design and manufacturing feasibility responsibility for over (140) injection molding tools that were located on (3) different continents – Japan, China and North America.
• Improved throughput over 15% in only 1 month’s time frame. Eliminated roadblocks (processes and personnel issues).
• Increased effectiveness in development process that increased productivity and reduce overall development time 50% in documentation associated with the integration of engineering data into process.
• Reduced post-production release tooling revisions over 28%; established effective communications on product changes.
• Chosen as engineering representative to travel overseas and act as representative to support Asian product launches.
Manager – Design & Computer Aided Design, Supplier Liaison & Senior Designer (Positions executed simultaneously)
Collins & Aikman – Specialty Products Group (Open Air Systems-Convertible Top) Troy, MI / 2003 - 2005
• Direct staff of 7 highly skilled engineers throughout 2 departments in design for complex systems for convertible top applications.
• Provide design, engineering, manufacturing and managerial leadership for entire division.
• Develop and manage engineering and computer aided design (CAD) budgets for entire division.
• CAD coordinator and supplier liaison responsibilities for all design related activities.
• Design major convertible top assemblies and components; i.e. stampings, castings and injection molded parts.
• Implement design for manufacturing (DFM), assembly (DFA) and serviceability (DFS) principles. CATIA V4 (kinematics, solids, wireframe), CATIA V5, IDEAS and Unigraphics (UG).
Select Accomplishments:
• Achieved quarterly cost avoidance in licensing fees of over 20%. Combined areas of similarity, eliminated unused/non-value licenses and renegotiated annual and maintenance fees. Financial gain contributed to increased margins.
• Selected to act as division’s representative to major OEM customers (General Motors, Ford and DaimlerChrysler). Developed proactive responses to anticipated questions and used visionary approach to finding solutions to potential issues.
• Improved organizational communication flow resulting in 25% product release time reduction. Future projects quoted more effectively and with greater level of fidelity through similar team collaboration.
• Reduced tooling change cost 30%, incorporating Design for Six Sigma and Design for Manufacturing Principles.
• Increased engineering throughput over 20% via establishing historical engineering documentation and metrics
Supervisor – Design, Senior Designer
DaimlerChrysler (OEM) Auburn Hills, MI / 1998 - 2003
• Promoted from Design Engineer Lead to Manager to provide direction and supervision for staff of 20 design engineers.
• Oversee designs of entire body-in-white vehicle system for international product launch support-concept through production.
• Establish corporate efficiencies through productive collaboration with joint venture organizations.
• Utilize and manage CATIA V4 (solids, generative shape modeling, wireframe).
• Represent design personnel in development of new vehicle platforms, from concept through production release.
• Establish corporate efficiencies through productive collaboration with joint venture organizations.
• Represent team as subject matter expert in areas of computer aided technologies and processes.
Select Accomplishments:
• Patented 4 unique product designs in only 5-year period and put into production immediately following patent awards. Products increased vehicle performance on impact, integrated several components into 1 while improving overall functionality, and structural component that also served as attachment foundation for class ‘A’ finish panel.
• Subject Matter Expert representing engineering in processes/procedures of computer aided technologies/development. Computer aided design software became catalyst for developing design templates for integration in multiple programs
• Streamlined company-wide corporate data management system, eliminating non-value added processes in product releases.
Design Leader Technical, Senior Designer
Saturn Corporation – General Motors Division (Interior & Exterior Automotive Systems-OEM) Madison Heights, MI / 1988 - 1998
• Progressively promoted from Senior Designer to Design Leader Technical Interior over 12 designers then promoted to Design Leader Technical Exterior over 30 designers.
• Coordinate complete engineering, packaging and manufacturing activities for from concept through production.
• Coordinate, document and resolve computer aided design issues.
• Responsible for homologation design of vehicles to Asian markets.
• Manage studio and engineering activities early in concept development stages.
Select Accomplishments:
• Recognized for widespread knowledge base in interior and exterior groups. Developed shared and integrated efficiencies.
• Represented engineering group in diverse team that led to development of strategy implemented across entire division. Key enabler to success of organization using internal customers as fundamental part of overall planning.
• Managed engineering interface between upfront studio and packaging activities for interior and exterior of vehicle (normally 2+person role), maintaining vehicle development uniformity with 1 individual.
• Key designer of vehicle development engineering team, developing non-corrosive, non-dent able exterior panel design using polymer materials. Processes still being used in today’s vehicles.
• Diverse team member to provide foundation of start-up organization. Simultaneously involved in development of company, new teams/relationships, processes/procedures creation, unique product invention, and manufacturing facility assembly.
PROFESSIONAL DEVELOPMENT & AFFILIATIONS
Bachelor of Business Administration- Industrial Administration / Central Michigan University / Summa Cum Laude with Honors
Associate of Applied Science-Mechanical Engineering / Oakland Community College
Philpot School of Automotive Design Graduate / 9 month Specialized School for Elite Automotive
Creative Thinking & Problem Solving
Design of Experiments
Root Cause Analysis
Design for Assembly
Design for Manufacturing
Design for Assembly
Design for Service
Design for Six Sigma
Society of Automotive Engineers International
Automotive Management Professionals
Renewable Energy Business Network
Global Foresight
Motor City Connect
CleanTech
Green
Future Trend
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