Thorsten Sauer

**** ************ *** ** ( Alto, MI 49302 ( 616-***-****

( abi6lv@r.postjobfree.com

Executive Summary

Commitment Leadership Integrity

Offering 20+ years of Verifiable Accomplishment in Manufacturing and

Engineering Services

A proven visionary and strategic leader that translates business strategies

into maximum profits commensurate with the best interest of customers,

employees and the consumers. An expert in enhancing profitability;

developing and implementing efficient processes that support growth and

produce the highest quality output. Very knowledgeable of automotive

standards and proven track record of implementing the necessary controls to

ensure compliance. Dedicated to maintaining a reputation built on quality,

service, and uncompromising ethics.

Areas of Expertise / Core Competencies

Operations Management Strategic / Tactical Staff Development &

Plant Start-up Planning Leadership

Product Launch Vender Sourcing & Forecasting & Cost Benefit

Process Improvements Analysis Analysis

Lean Manufacturing Contract Negotiations Inventory Management

Business Development Relationship Management Cost Containment

5-S Workplace Department Management ISO/IEC 17025 Implementation

Organization Environmental Regulations TS 16949 Implementation

Bilingual (German / English)

H&S Regulations/Systems

Professional Experience

Magna Mirrors of America, Inc

Duncan Facility - Spartanburg, SC 29303

2010 - Present

Engineering /Quality Manager

Provide leadership in Engineering and Quality activities to establish

systems and drive improvements of current products and processes. Direct

and coordinate Quality and Continual Improvement activities to achieve

superior results while obtaining optimum efficiency and economy.

Responsible for supplier development. Development of supplier drawings and

specifications to ensure product reliability and quality. Providing methods

to reduce the cost of daily operations by continually improving processes

and eliminating waste.

. Completed overhaul of DFMEA's PFMEA's, Control Plans, work instructions

and in-process checks.

. Implementation of quality system

. Application of Lean manufacturing principals

. Implementation of 5-S workstation practices

. Implementing one-piece workflow to assembly processes

. Full review of all assembly equipment and error proofing features,

process setups and process capability.

. Maintain contact with customers, suppliers, manufacturing, and support

resources to ensure that Quality Assurance systems are meeting

objectives.

. Directs, implements, and maintains operational-level strategies and

objectives and monitors performance against plan.

. Leading project to in source the paint process to improve quality and

cost

. Establishing all design verification testing plans

. Obtain ECE and CCC certifications for automotive products

Achievements:

. Identified large numbers of existing and hidden quality problems and

implemented effect ive counter measures resulting in design changes,

supplier quality systems improvements, updated error proofing and process

improvements

. Eliminated 3rd party inspections in the manufacturing location, sequence

centre and a number of suppliers saving 160k per month

. Eliminating incoming and outgoing expedite freight by 110k per month

. Eliminated GP12 containment in all locations improving profitability and

securing customers for return business. Received additional Mercedes and

BMW replacement business awarded.

. Reduced external PPM level to all Customers and internal PPM levels.

. Reduced incoming defective material occurrences and severity.

Magna Mirrors of America, Inc

Engineering Center - Kentwood, MI 49512

2003 - 2010

Engineering Services Manager /Chief Engineer (2004-2010)

After Magna's acquisition of Donnelly, I was tasked with the consolidation,

work standardization and management of the Design, Testing and Prototype

for the two companies and combine them into one newly established

Engineering Center. In addition, I was tasked with managing the testing,

design and prototype services out of the new facility as a profit center.

I successfully executed the tasks and proved to be very successful,

generating positive funds throughout the recent downturn in the automotive

industry.

. Developed processes and successfully implemented ISO 9001 for Design and

Testing allowing me to develop a customer base with outside companies

(within 6 months)

. Developed processes and successfully implemented ISO/IEC 17025 and

achieved A2LA Accreditation of the testing Laboratory (within 8 months),

providing a foundation for new business

. Achieved TS Compliance for all of the services which support the

automotive sector of our business

. Implemented Quality control systems for new product engineering, design

functions and design verification testing departments.

. Performed studies to identify all cost drivers and developed methods that

successfully reduced the cost of our services and improved performance

. Led all facility management activities which include implementation and

maintenance of Health and Safety and Environmental systems, coordinating

building maintenance and facility expansion activities

. Conducted regular risk assessments and quality assurance reviews to

evaluate compliance with requirements and to identify potential gaps in

policies, procedures and business processes

. Provided DFMEA, PFMEA training to engineering staff.

. Translation of customer specifications and standards from German to

English

Achievements:

. Substantially reduced overhead and operating costs through work

standardization and improved planning processes.

. Overhead was reduced with 37% of the Design group, 52% of the Prototype

and 28% of the Laboratory.

. Standardized design features and implemented a design library, best in

class database and lessons learned library.

. Cost of poor quality in the design department was reduced for the last

two years to less than $16,000. This relates to tooling releases of

approximately $15,000,000. The cost of poor quality in the design

verification area was less than $10,000 over the last two years and

supported testing activities for more than $2,000,000.

Purchasing Manager of North America (2002-2003)

Guided the creation of a strategic purchasing group by centralizing the

purchasing functions and maintaining only tactical buyers in the

manufacturing facilities. Led the purchasing group through a massive cost

evaluation and reduction project. Lead the selection of strategic

suppliers by evaluating customer needs, specifications, quality systems and

performance. Established strategic supplier relationships. Guided

supplier development activities for quality systems and manufacturing

processes. Gathered data and performed studies on components produced

within our divisions for plastic injection molding, paint and assembly.

Based on these studies, I categorized the information and was able to

identify Best-In-Class processes for each component. I facilitated several

VA VE workshops for outside mirror and door handle assemblies. Conducted

benchmark activity which broke down competitor parts by component and

gathered data to compare materials and processes used and identified

changes to our designs to reduce cost.

. Developed processes and utilized analysis tools to evaluate cost models

for various commodities.

. Analyzed low cost countries price structures to identify potential new

suppliers.

. Identified new suppliers to reduce cost.

. Initiated VA/VE workshops to optimize manufacturing cost.

Achievements:

. Successful centralization of purchasing and establishing a strategic

supply base through the evaluation and reduction project yielded $19.8

million in savings to the organization.

. Selecting a strategic supply base resulted in a more streamlined supply

chain with fewer and stronger suppliers.

. Noticeable improvement in purchased component quality still evident years

after completing this project.

. 80% of the selected suppliers managed the economic downturn and are still

supplying Magna with product.

Magna Powertech - Kentwood, MI 49512

1997 - 2002

General Manager

Led the successful start up of a new outside mirror actuator division.

Successfully managed the facility until the product transferred to Mexico.

As part of the start-up, I designed all of the assembly equipment and

defined the production methods for a new mirror actuator. I had full P&L

responsibility for this facility. The facility grew from start-up to a $30

million dollar facility producing five different product lines, all prior

to the purchase of Donnelly by Magna. This purchase provided Magna with

access to a manufacturing facility in Mexico and the decision was made to

move this product and close the facility in order to reduce labor cost

further. I managed the entire transfer and trained their personnel as well

as provided on-site support. This meant spending time in Mexico to ensure

the product performed to specification and obtaining customer sign-off.

. Established all systems to manage this new facility effectively.

. Established a well trained very motivated work force.

. Develop an entirely new supply base for this product due to its

functional requirements and unique components.

. Developed automated and semi automated assembly equipment.

. Implemented a highly effective materials management system yielding high

inventory turns.

. Established the supplier base for this product.

. Created and managed a profitable company.

Achievements:

. Managed the facility to be profitable after 5 month from the start-up.

. Produced a lower cost actuator with better performance characteristics.

. Grew the facility to $30 million+ manufacturing location.

. Implemented an inventory control system and a manufacturing planning

process.

. Achieved TS certification.

. Achieved better quality ratings then our sister company in Europe, which

had a thirteen year head start.

Magna Lowell Engineering - Alto, MI 49302

1994 - 1997

Maintenance Manager

I successfully managed the implementation of automated equipment,

development of assembly aids to reduce quality issues and the design and

manufacturing of test equipment capable to test product coming off the

production line as a 100% in line inspection for performance and

completeness. Took over the maintenance team, trained personnel and led the

implementation of a predictive maintenance program. I was part of a

workshop evaluating the option to develop and produce electromechanical

actuators. This workshop resulted in opening up a new plant focusing on

the mass production of actuators. I was tasked to manage the setup and

start-up of a new facility focusing on this new product.

. Established a predictive maintenance program.

. Set up a new paint line.

. Developed new test equipment and improved assembly methods.

. Corrected quality systems problems in our program management process.

. Root causing of product failures and implemented corrective actions.

Achievements:

. Setup a new paint line and achieving a 97% first time quality.

. Implemented a predictive maintenance program reducing machine downtime by

8%.

. Reducing assembly related quality failures at the customer level to 0.

Magna Ligma Corporation - Nashville, IL 62263

1990 - 1994

Maintenance Manager

After accepting the offer to work for Magna in the USA I led the technical

maintenance team and trained all technical maintenance personnel to be able

to maintain and repair the manufacturing lines independently. Supported

the growth of this facility by setting up and improving further equipment

transferred into this facility from acquisitions from other companies in

the US. While working in the US, I was sent to two additional facilities

where I improved their equipment performance, which led to increased

profitability, improved quality and process reliability all while

maintaining the main plant production equipment and maintenance systems.

In 1994, I was sent to a Siemens facility in Austria where I evaluated an

automated paint system and the possibility to modify the system to be used

for painting automotive rear view mirrors. Based on the results of my

evaluation, I was tasked to manage the disassemble, transport and setup of

the system including all needed modifications to get the paint system up

and operational in the US. After successful implementation of this

project, I then transferred full time into the Magna Lowell Engineering

facility.

. Established a preventive maintenance program.

. Set up various manufacturing equipment.

. Reduced quality issues and improved production output.

. Trained technical maintenance personnel.

Achievements:

. Eliminate all late shipments resulting from pour equipment and process

performance.

. Improved the process cycle time of the 6 major production lines by 23% to

31% better then original design.

. Implemented a preventive maintenance program.

. Improved the profitability of the organization.

AMA Werke - Germany 1987 -

1990

Electrical engineer

. Worked as an electrical engineer for a company which developed new

processes and manufacturing equipment for a verity of industries.

Assignment was to design, direct the building and program the computer

systems controlling the equipment. I was sent to the US as the project

leader and spent 18 months in the US setting up all equipment in a new

150,000 sqft building supplying parts for Ford, Chrysler and BMW. The

next assignment brought me to Italy working on a similar product for

FIAT. Issues with the technical abilities of the maintenance team trying

to maintain the equipment in the US causing delivery and quality issues

triggered the request for me to permanently work for Magna in the USA.

. Designed the electrical control systems, managed building the electrical

systems and programmed PLC's.

. Managed the project in the US for my German employer.

. Managed Union relationships with American work force.

. Interpretation and understanding of customer needs and requirements

. Managed the launches of new equipment.

Achievements:

. Set up equipment per customer requirements and achieving all Contractual

performance criteria.

. Successfully managed the relationships with Unionized skilled workers for

their participation with the equipment installation effectively to

maintain the time line for the production launch.

. Launched all equipment on-time and within budget

Professional Organizations and Affiliations

Member of ESD - The Engineering Society of Detroit

Member of SAE - Society of Automotive Engineering

Education

Degree in Electrical Engineering Germany (Comparable to Masters)

Fachhochschule for Mechanical and Electrical Engineering - Germany

Professional Development / Skills

Process Mapping DFMEA & PFMEA

Dale Carnegie Leadership Training Value Stream Mapping

Dale Carnegie Sales Training ISO/IEC 17025 Training

8-D Problem Solving TS 16949 Training

VA/VE Internal Auditing

5-S Workplace Organization Speak fluent German

Microsoft Word, Excel, Powerpoint Microsoft Project

Mercedes Quality System (SQMS)

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