Engineer Quality Assurance

MARK L. GOTTULA

**** ******** **** *********: 513-***-****

Harrison, OH 45030 Cell: 513-***-****

********@********.***

PROFESSIONAL SUMMARY

Accomplished engineer with strong mechanical and analytical ability in the automotive industry in quality control, field or

customer service and truck product design .The go-to guy routinely recruited by senior management to attack and solve

major transmission issues in a cost effective and timely fashion at Ford plants. Possesses the unique skills to review the

design, process sheets, dimensional control plan, charting and physical parts to identify and resolve quality issues in the

assembly of automatic transmissions. Extensive experience in the diagnosis, teardown and repair of automatic

transmissions. M.A., Western Kentucky University, M.S., Eastern Kentucky University. Specific areas of expertise include:

• •

Assembly Plant Transmission Liaison Supplier Quality Assurance Issue Resolution

• •

Transmission Launch Experience Heavy Truck Product Design & Testing

• •

Assembly Plant Find & Fix Campaigns Six Sigma Green Belt

PROFESSIONAL EXPERIENCE

NEXTEER AUTOMOTIVE

(FORMERLY GENERAL MOTORS, SAGINAW STEERING), SAGINAW, MI 2010-PRESENT

Field Support/Supplier Quality Engineer (Nexteer – Delphi)

Regional Representative for Nexteer Automotive and the primary contact for driveline and steering products at OEM plants

in Kentucky, Indiana, and Ohio. Resolve commercial and technical issues and improve customer relations as well as

provide manufacturing and plant engineering support to Saginaw based operations. Perform weekly visits to TMMK (Toyota

Kentucky), TMMI (Toyota Indiana), Ford Kentucky Truck Plant, General Motors at Lordstown, Ohio, and General Motors at

Trotwood, Ohio. Provide field support by addressing quality issues, setting up sorts, and diagnosing and troubleshooting

service and repair issues at OEM plants. Supervisor: Dave Cole, 989-***-****, 989-***-****.

INGERSOLL RAND SECURITY TECHNOLOGIES, BLUE ASH, OH 2008-2009

Quality Control Engineer (STEELCRAFT)

Worked through an agency performing machine capability studies on blanking, forming, and roll-forming machines as well

as finished steel door products. Designed and built fixtures to accomplish capabilities studies and used Mini-Tab to

determine machine capability. Supervisor: Mike Barham, 513-***-****.

FORD MOTOR COMPANY 1976-2008

Sharonville Transmission Plant, Sharonville, OH (2001-2008)

Supplier Quality Assurance Engineer (Supplier Development)

Resolved supplier quality issues by analyzing part specifications to determine specific problems and implemented

corrective actions that assure design intent. Consulted with process engineers to resolve assembly problems by identifying

supplier processes issues and assure conformance to manufacturing specifications.

• Managed and supervised incoming and outgoing quality of $120M of torque converters annually.

• Developed supplier counter measures and secured financial credit for nonconforming parts when suspect part problems

arose that insured transmission assembly parts met print specifications.

• Created the teardown return procedure for dealer returned defective torque converters determining systemic problems

and implemented prevent reoccurrence actions.

• Improved outgoing product quality assuring print specifications were met maintaining customer satisfaction.

MARK L. GOTTULA – Page 2

Assembly Plant Liaison (Customer / Field Service Representative)

Created and selected a team of master technicians to resolve large problems when a transmission crisis arose or launches

needed to be managed at assembly plants. Initiated teardown procedures and trained technicians to repair multiple

transmissions. Worked individually on smaller transmission problems.

• Supervised a solenoid campaign to prevent a $3.2M a month charge for defective solenoids by testing and repairing

vehicles prior to customer delivery. Root cause was identified and a product change was implemented eliminated the

problem.

• Led a team of 15 technicians and repaired $3.0M of vehicles by tearing down transmissions at assembly plants after

sorting 3,000 suspect vehicles preventing excessive warranty cost due to bad transmissions. Identified root cause and

through the 8D process the vendor implemented prevent reoccurrence actions.

• Organized and implemented a campaign to repair defective motor home units and prevented park issues from getting to

the customer, keeping warranty costs down.

• Routinely went to Ford vehicle plants when transmission problems arose to retrieve defective automatic transmissions

or supervise the repair campaign. Single transmission issues were retrieved and root cause was identified. Multiple

transmissions were repaired in a timely fashion at a cost savings.

Vehicle Test Engineer

Managed vehicle testing to satisfy the engineering specification requirement for daily transmission testing and conformance.

• Tested instrumented vehicles daily evaluating the transmission shift feel, function, and overall transmission quality.

• Trained and supervised the testing of early built transmissions into prototype vehicles that achieved excessive mileage

in a short time assuring the reliability of new model transmission.

Warranty Analyst

Managed the transmission teardown database and analyzed results for the 4R100 transmission product line. Tracked all

4R100 solenoid defects and subsequent Eaton analysis to determine prevent reoccurrence actions.

• Developed and prepared the daily morning report from assembly plant information, supplier information, and in-house

departments in order to disseminate the information to rest of plant informing them of emerging issues. This facilated

root cause analysis and future problems were prevented.

• Tracked and charted assembly plant transmission problems using the Eight Disciplines (8D) process and implemented

prevent reoccurrence actions.

Truck Vehicle Development Center, Dearborn, MI (1999-2000)

Ongoing Product Development – Truck Chassis Product Designer

Designed new parts and assemblies to correct dealer warranty issues.

• Corrected dealer warranty and assembly plant problems by designing new parts reducing warranty costs.

• Created layouts, sketches, and detail drawings on F-250 through F-550 vehicles insuring new parts would assemble

properly resolving specific plant and customer warranty issues.

Kentucky Truck Plant, Louisville, KY (1976-1998)

Plant Vehicle Team - Special Launch Assignment

Worked on a special launch team assisting Dearborn Product Engineering in the resolution of launch issues.

• Solved chassis build issues for 1998 model launch of F-250 - 550 assuring early built units were problem free.

• Supplied data to product engineering in Dearborn resolving front brake rotor run out issues on new model launch

vehicles (F-350) and reducing brake system warranty costs.

• Worked through dealer service managers to examine, inspect, and repair specific manufacturing concerns related to

assembly plant steering wheel issues on early built units at dealerships preventing a recall.

Plant Vehicle Team - Product Engineering Designer

Designed and tested new parts resolving manufacturing concerns and warranty issues.

• Created the engineering drawings and design work necessary to fix warranty problems on F-250 through F-550 light

and heavy trucks. Warranty costs decreased and customer satisfaction increased.

• Examined vehicles and prepared all necessary calculations, testing, layouts, and sketches resolving engineering

problems utilizing the 8D process which prevented assembly plant and warranty problems.

MARK L. GOTTULA – Page 3

Special Order Design Department, Heavy Truck Product Engineering Designer

Engineered and designed parts necessary for Special Vehicle Product Engineering of heavy truck components and

assemblies offering unique specialized heavy truck options on fleet orders of 20 units or more.

• Prepared layout documents, drawings for bids, new heavy truck component designs, installation sketches, and body

builder drawings that documented the engineering of special heavy truck options requested by the customer for a

specific unique business application.

• As a special problem report coordinator, handled the resolution and solving of manufacturing concerns related to the

building of heavy trucks that insured recently engineered parts could be assembled.

Product Engineer Illustrator

Created product illustrations from existing illustrations on new layout documents.

UNIVERSITY OF LOUISVILLE, Speed Scientific School, Louisville, KY 1983-1986

School of Engineering Faculty Member - Instructor for engineering graphics and design.

EDUCATION

Western Kentucky University, Bowling Green, KY Eastern Kentucky University, Richmond, KY

M.A., Industrial Education, 1977 M.S., Industrial Technology Management, 1990

B.S., Industrial Education, 1976

SPECIAL SKILLS

CMMS, OUTLOOK, PDGS, PROFS, IDEAS, Geometric Dimensioning, Statistical Process Control, Global 8D Process,

Design for Assembly, Robustness Imperative, Preventive Recurrence Training, Reliability Training, Diesel Engine Workshop,

Collaborative Decision Making, Six Sigma Green Belt, CAD experience on IDEAS

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