Engineer Manager

ROBERT J. WARNKE PE

**** *** ***** ***** . ******, OH 43612 . 419-***-****

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

CONTINUOUS IMPROVEMENT LEADER

SUMMARY OF QUALIFICATIONS

Certified ASQ Black Belt Professional Engineer with broad-based experience

in cost savings. Major strengths in problem solving, process optimization,

project management, auditing and warranty cost reduction. Dependable

results-oriented manager with strong technical, analytical and presentation

skills. Able to strategize and prioritize to ensure project completion

within deadlines. Detailed-oriented, accurate and persistent. Engineering

and Manufacturing Production experience.

PROFESSIONAL EXPERIENCE

DANA HOLDING CORPORATION, Driveshaft Division Toledo, Ohio 1997 - 2009

Master Black Belt 2005-2009

Mentored, coached and managed Black Belts to ensure timely completion of

all product objectives and implementation of savings. Coordinated saving

activities and Kaizen events with other savings groups. Worked with

operational leaders to develop new projects and report results.

. Exceeded goals by several million dollars per year, savings per Black

Belt consistently increased.

. Streamlined process to shorten time to complete projects by one month.

. Invented product selection and prioritization process to generate

additional savings.

. Created project database and conference calls to standardize processes

and replicate successes.

. Maintained savings during bankruptcy; times of high turn over and

restricted capital.

. Leveraged BB resources to address chronic issues including Quality PPM's.

. Presented projects at Lean Six Sigma Symposium, Corporate Operating

Committee Meeting, ASQ Meeting, BGSU and University of Toledo MBA

classes.

. Educated all locations in Six Sigma Continuous Improvement philosophy,

assisted in training.

Six Sigma Black Belt 2001-2005

Lead cross functional teams to achieve continuous improvement goals on

major business initiatives using Lean Six Sigma tools and methodologies.

. Changed suppliers to reduce cost and improve products performance.

. Performed DOE's to solve end of the line testing excessive rejection

rates.

. Projects completed for Part number reduction, Manpower leveling, Energy

savings, Dunnage standardization, Shipping supplies, Inventory reduction,

Outsourcing, Customer owned tooling, Process Improvement, Scrap

reduction, Label standardization, Supplier optimization, etc.

. Achieved highest savings for all Black Belts, over $800,000 per year.

Global Warranty and Technical Service Manager 1997-2001

Managed global driveshaft warranty for automotive through class 8 truck

OEM's. Selected for this responsibility to get expenses that had been

increasing at an exponential rate under control.

. Created process to forecast detailed cost projections for warranties by

product and OEM.

. Devised coding / tracking system and segmented data to identify

responsible plants and suppliers.

. Presented actionable information to Operations and Engineering

identifying areas of concern to effectively attack root causes to drive

changes to improve product performance.

. Contributed to DFMEAs, PFMEAs, Control Plans and APQP processes.

. Identified design issues that had previously been attributed to assembly.

. Designed tracking process to measure effectiveness of product changes and

identify different failure rates for each OEM configuration.

. Audited, scored and presented findings to SUV and Heavy Truck OEM

assembly plants to validate proper installation of driveline products.

. Negotiated and made site visits with Fleets to controlled policy, recall

and swap out expenses.

. Reduced liability exposure by investigating product liability cases and

making site visits.

. Audited product manufacturing and assembly plants to identify non-

conformances.

. Reduced warranty costs by 27% by improving claim process and tightening

administration.

DANA CORPORATION, Transmission Division Toledo, Ohio 1977 - 1997

Product Reliability and Customer Service Manager 1989-1997

Managed transmission and transfer case warranty for SUV through class 8

truck OEM's

. Developed highly accurate spreadsheets to forecasted expense by product

model and determine extended warranty contract cost.

. Negotiated warranty agreements and Fleet swap out programs, trained field

personnel.

. Advised Corporate Legal in legal actions and insurance claims.

. Reduced Manpower by 33% due to process efficiency improvements and

computerization.

Engineering Records and Distribution Manager 1986-1989

. Improved routing of bills of material, change notices, sample part

releases, deviations, mail, supply ordering, maintenance, office union

payroll, etc.

. Reduced Manpower by 38% increased through-put and eliminated overtime.

Application Engineer 1984-1986

Approved OEM product applications, made Customer presentations, created

technical literature, failure analysis, troubleshoot, resolved Customer

issues and optimized product supersessions.

Product Engineer 1979-1984

Improved designs, developed and tested products. Solved production issues.

Disposed of deviated material. Worked with suppliers to improve

performance.

Production Department Supervisor 1977-1979

Supervised machining and grinding production UAW personnel, scheduled

production and allocated manpower. Total department size was 54 people.

Reduced service part backlog.

EDUCATION

Masters in Business Administration, Bowling Green State University, Bowling

Green, Ohio

Bachelor of Science in Mechanical Engineering, University of Toledo,

Toledo, Ohio

LICENSES and CERTIFICATIONS

Certified Six Sigma Black Belt certified by American Society for Quality

Registered Professional Engineer licensed by the State of Ohio

PROFESSIONAL MEMBERSHIPS

Senior Member of American Society for Quality (ASQ)

Committee member of Society of Automotive Engineers (SAE)

Automotive Industry Action Group (AIAG)

American Trucking Association Member (ATA)

SKILLS DEVELOPMENT

Four weeks Six Sigma Black Belt Training, Owens College review class plus

Seminars

Shainin Red-X Problem Solving and Rolling Top 5 Training plus Symposiums

Minitab Statistical Software Training

Value Stream Mapping Training

Various Lean Manufacturing Training, Webinars and Seminars

Various Technical and Quality Training

Team member of Dana Driveshaft Malcolm Baldrige National Quality Award

winning application

Dana Quality Leadership Award Senior Examiner and Auditor

QS9000 Internal Auditor

Mike George of the George Group requested BB project to be used in one of

his books

Karrass Effective Negotiating Training

Dale Carnegie Effective Communications and Human Relations Training

Delta Gamma Sigma National Scholastic Honorary (top 10% of class) - BGSU

Dean's List and Pi Tau Sigma Mechanical Engineering National Honorary - UT

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