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Project Manager Engineer

Location:
Ferndale, MI, 48220
Salary:
negotiable
Posted:
August 18, 2010

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Resume:

KARL SONNENBERG

*** ****** ******, ********, ******** 48220

248-***-****

248-***-****

r3eruq@r.postjobfree.com

SENIOR ENGINEERING PROFESSIONAL

QUALIFICATIONS PROFILE

- Seasoned, diligent, and dynamic achiever with more than 20 years of experience in automotive and interior engineering spanning all aspects of design, development, release, project / program management, quality assurance, and packaging. Internationally competent and intuitive liaison with accomplish-based record of success in streamlining major projects and initiatives abroad.

- Proactive and integrity-based with synergistic set of technical knowledge and advanced written and communication skills, complemented with substantial success in assisting companies to develop products that maximize revenue and expand market share

- Experienced working and coordinating with cross-functional departments, including, OEM Studios, Concept Engineering, Product Development, Production and Continuous Improvement, Advanced Engineering, Quality Assurance, Supplier Management, PDfSS, and New Business Acquisition departments

- Expertise in the preparation and maintenance of all supporting documentation, including BOM, DFMEA, PFMEA, DVP&R, 8Ds, issue tracking, project timing and scheduling, change control, quality, craftsmanship, benchmarking, VAVE, and safety testing ESOW (Engineering Statement of Work), Material Cost Reduction, and ED&T Component Costs

- Proficient in MS Office Suite, including Excel, Word, Project, PowerPoint, Office, and Outlook; as well as WERS, AIMS, Digital Buck, TCE, C3PNG, Teamcenter, SharePoint, Unigraphics and CATIA v5; with general knowledge and experience in Alias, and Pro/E

- Fluent in English with basic knowledge of Japanese and Chinese languages

AREAS OF EXPERTISE

STRATEGIC PLANNING ~ PRODUCT DESIGN AND DEVELOPMENT ~ DESIGN AND RELEASE ~ PROCESS DEVELOPMENT ~ REENGINEERING ~ PROJECT / PROGRAM MANAGEMENT ~ PRODUCTION OVERSIGHT ~ INVENTORY AND MATERIALS MANAGEMENT ~ SAFETY AND QUALITY ASSURANCE ~ COST REDUCTIONS ~ ROOT CAUSE ANALYSIS / TROUBLESHOOTING ~ CONCEPT DESIGN ~ SUPPLIER MANAGEMENT ~ VALIDATION ~ TECHNICAL WRITING ~ ILLUSTRATIONS ~ DRAFTING

PROFESSIONAL EXPERIENCE

CVG-Commercial Vehicle Group

(Global Seat Engineering Division) - Columbus, OH

SENIOR ENGINEER / LEAD LIAISON - International Assignment Dec 2008 - Mar 2010

Directed and ensured the success of an international assignment with Volvo P3 and Nissan Diesel in Ageo, Japan as well as with CVG manufacturing plant in Shanghai, China.

- Functioned as lead program management and engineering development liaison responsible for maintaining coordination in program activities

- Managed customer relations and streamlined procedures in prototype and production engineering and development

- Initiated improvement in supplier management, quality control, root cause analysis, scheduling, and logistics

G-Tech Professional Staffing / Ford Motor Company

(PDC North American Seat Engineering) - Dearborn, MI

SENIOR DESIGN AND RELEASE / DEVELOPMENT ENGINEER / PROJECT MANAGER Jul 2005 - Jul 2008

Optimized and managed the design and release of seat component systems.

- Assigned leadership of the Ford Escape, Mariner, and Mazda Tribute complete seat warrantee and supplier management of root cause and analysis and corrective action implementation – (2005 - 2006)

- Appointed as the lead engineer on all rear head restraint design and development of new FMVSS 202a regulation for production and advanced models of all Ford Motor Company vehicles – (2006 - 2008)

- Patent pending on a seat system for improving 202a IIHS performance

Collins & Aikman Corporation (Interior Component / Carpet and Acoustics Group) - Madison Heights, MI

SENIOR PRODUCT / DESIGN RELEASE ENGINEER / PROGRAM MANAGER Sep 2004 - Jul 2005

Managed and fine tuned program management, design, development, and release of interior components, carpet and acoustics for all Toyota programs in the Carpet and Acoustics International Division.

- Key driving force in the successful completion, development, and launch of the new “Quiet Tuned” interior carpet acoustics package and interior plastics for the GM Buick Lacrosse

MSX International Johnson / Controls, Inc. (Automotive Group, Ford Seating Division) - Plymouth, MI

SENIOR PROGRAM RELEASE ENGINEER / PROJECT MANAGER Aug 2003 - Sep 2004

Chosen by JCI from Visteon Navigator/Expedition Engineering Team to lead and ensure the seamless transition and launch of the Ford Expedition and Lincoln Navigator seat programs during JCI’s purchase of Visteon’s Seating Division.

- Led the comprehensive design and timely release of complete seats, components, and restraint systems for all rows from project inception though production launch and beyond

- Facilitated and streamlined multiple functions, including design sessions, materials management, project scheduling, QA, VAVE / MCR, NVH, PDfSS, root cause analysis and resolution, continuous improvement, as well as craftsmanship

- Ensured that products meet customer and company expectations for key milestone events for quality, craftsmanship, safety, reliability, and cost

PGK / Invenio Engineering Services - Warren, MI Sep 1991 - Aug 2003

Visteon Corporation (Interiors and Seat Engineering - Ford Division) - Chesterfield, MI

PROGRAM MANAGER / LEAD PRODUCT DEVELOPMENT ENGINEER Nov 2001 - Aug 2003

Led and aligned program management as well as continuous engineering and manufacturing oversight and leadership for Visteon Corporation.

- Played a pivotal role in the development and test validation of seats and occupant restraints for the 2003 and 2004 2nd and 3rd row Ford Expedition and Lincoln Navigator

- Managed and motivated team members toward efficiency improvement while overseeing program management and product design development

- Maintained organization of schedule and compliance with quality assurance, along with FMVSS test validation, packaging, continuous improvement, quality, supplier management, craftsmanship, benchmarking, root cause analysis and corrective action implementation for NVH, MCR, and production line issues

- Produced and maintained error-free documents, including BOM, DFMEA, DVP&R, issue tracking, safety sign off, VAVE, action plan timing and scheduling, as well as change control while acting as a liaison with Ford Engineering Team and the Ford Assembly Plant personnel

PRODUCT RESIDENT ENGINEER / LIAISON (Lear Corporation) Nissan Automotive Advanced Engineering) International Assignment - Atsugi, Japan Jan 2000 - Nov 2001

Piloted an international assignment for Lear’s Nissan office in Atsugi, Japan; served as project resident engineer / project manager from concept design to production of seating systems and component packages.

- Instrumental in the successful opening of the Lear, Atsugi, Japan office dedicated to Nissan business

- Filed and obtained approval for US and international patent on a seat mechanism - Patent # US 06679536 B1,

‘An Articulating Rear Seat System’

PRODUCT / PACKAGING DEVELOPMENT RELEASE ENGINEER / PROJECT MANAGER

General Motors (Advanced Engineering Seat Systems Division) - Warren, MI Jun 1999 - Jan 2000

Delegated to manage a range of seat and component design projects for Lear Corporation - GM Seat Systems Division, and Lear International Division

- Key participation in all aspects of engineering development and program management from concept through production of current and advanced vehicles for the GM Chevrolet Impala, Monte Carlo and Pontiac Grand Prix programs

PMT ENGINEER / PROGRAM MANAGER / LIAISON – Mazda Motor Corp.

International Assignment - Hiroshima, Japan (1998 - 1999) Jun 1998 - Jun 1999

Functioned as program manager and resident engineer at the Ford / Mazda PMT and Design Staff Engineering Center in Hiroshima, Japan; held responsible as program manager and engineering development liaison with multiple USA and Japan teams and departments.

- Managed and ensured timely resolution of customer issues; achieved and exceeded all milestone dates and requirements

- Leader in the proficient oversight of all supporting documentation; including BOM, DFMEA, PFMEA, DVP&R, Issue Tracking, Project Timing & Scheduling, Change Control, Quality, Craftsmanship, Benchmarking, VAVE, and Safety, Prototype, & Production component & systems validation testing

LEAD ADVANCED PRODUCT

PACKAGING DEVELOPMENT RELEASE ENGINEER / PROJECT MANAGER

GM Assignments Sep 1991 - Jun 1998

Accounted for the proficient oversight of the research, design, and development of GM’s first Seat Integrated Restraint (ABTS) system. Appointed as a project manager for the Graphics/Illustration department and maintained coordination in graphics work, all quoting, budgets, presentations, scheduling, main customer liaison to ensure projects exceeded client expectations and delivery dates.

- Managed and maintained efficiency in all aspects of engineering design and program management, including all scheduling, supervision of designers, prototype builds, product and system FMVSS safety test validation, defined layout criteria; created and maintained all supporting documentation.

- Sustained continuous support to all phases of program, from concept through launch - GM Design Staff and GM Advanced Engineering and Technology Division

PRIOR EXPERIENCE

- Design Engineer - Contracted to GM Truck and Bus

- Design Engineer / Senior Concept Illustrator - Contracted to GM Advanced Vehicle Group

- Project Manager / Senior Concept Illustrator - Creative Universal, Inc. / GM Programs

- Design Engineer / Senior Concept Illustrator / Graphics Manager - General Dynamics / Classified Military Vehicle Programs

EDUCATION / CREDENTIALS

- Project Management Professional (PMP) and Six-Sigma Programs

New Horizons Inc. - Troy, MI (Expected Certificate Completion: Nov 2010)

- CAD: CATIA v5 R18 - CATIA Training Incorporated - Warren, MI (Completed Jun 2010)

- CAD: CATIA v5 R0 - Certificate of Completion ~ Macomb Community College - Warren, MI (2002)

- Program in Japanese Language (2000)

Oakland Community College - Orchard Lake, MI

- Shainin Studies (1997)

Lear Corp. / GM - Warren, MI

- CAD: Unigraphics (1995)

Certificate of Completion ~ Envisions, Inc. - Warren, MI

- CAD: Alias (1994)

Certificate of Completion ~ College for Creative Studies (CCS) - Detroit, MI

- Program in Art and Design (1993)

Macomb Community College - Warren, MI

- Course in Supervision / Marketing and Sales (1990)

Automotive Development Centre - Chicago, IL

- Coursework in Architecture (1971) - Maricopa Technical College - Phoenix, AZ

TRAINING AND CERTIFICATES

Commercial Vehicle Group Inc - Columbus, OH SharePoint

Ford Motor Company - Dearborn, MI (2005 - 2008) TREAD Act ~ Information Barriers Protocol ~ Annual File Review ~ Careful Communication ~ Annual File Review ~ Failure Mode Avoidance ~ FCPA Anti-Bribery ~ Records and Information Management ~ WERS ~ GPDS Timing ~ Unauthorized Commitments ~ Data Safeguarding ~ Standards of Corporate Conduct ~ CATIA v5 for Design and Release Engineers ~ Teamcenter Engineering for Engineers

Visteon Corporation - Allen Park, MI (2002 - 2003) Craftsmanship ~ 8Ds ~ Root Cause Analysis ~ Torque Management ~ Control Plan ~ Process Control ~ Quality Control ~ PPAP ~ DVP&R ~ DFMEA ~ PFMEA ~ Supervision ~ Design for Manufacturing, Safety, and Recycling ~ WERS

Johnson Controls, Inc. - Plymouth, MI (2003 - 2004) Craftsmanship ~ Welding Integrity ~ Design for Manufacturing, Safety, and Recycling

PROFESSIONAL AFFILIATIONS

Porsche Club of America

American Craft Council

AWARDS AND HONORS

- Who's Who listing ,1992, 1994 - 1996

- Patent # US 06679536 B1 'An Articulating Rear Seat System'

- Patent pending on a seat system for improving IIHS performance

- Outstanding Performance Award - Ford Motor Company - 2006

- Recognition of commitment and support of contributions and accomplishments - Ford Motor Company - 2007

- Merit Award – For exceeding customer expectations - Johnson Controls & Ford Motor Company –

Ford Expedition and Lincoln Navigator programs - 2004



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