DONALD H. COURTLEY III

**** ****** ****** *** 248-***-****

Shelby Township, Michigan 48317 abl7qb@r.postjobfree.com

CAREER SUMMARY

Engineering professional with 20 years of successful technical experience

in design, warranty, quality and problem solving. Special expertise in

warranty reduction and quality improvement at the design, supplier and

manufacturing levels of Fuel Systems, Exhaust Systems and

Chassis/Powertrain Hardware. Excellent at implementing innovative design

and manufacturing applications. Strong ability to identify, analyze and

solve problems using Shainin Red-X and other methodologies. Highly

respected for developing cost effective solutions while enhancing quality.

Ability to learn systems quickly. Known for resourcefulness and creativity.

Influential leader and coach with great interpersonal skills. Certified Red-

X Master.

PROFESSIONAL EXPERIENCE

RESOURCE TECHNOLOGIES CORPORATION, Troy, MI 2010-Current

Vehicle Exterior and Suspension Alignment, Resident Engineer

Chrysler Corporation - Sterling Heights Assembly Plant

Solved vehicle quality issues / assembly problems using Chrysler / Fiat

World Class Manufacturing methods. Led Design Engineers and Assembly

plant personnel to solve Customer Satisfaction Audit (CSA) perceived

quality issues on exterior trim, weather strips, garnish molding, glass,

mirrors, lighting, decals, emblems and chassis suspension alignment.

Coordinate engineering tryouts, and contain supplier quality issues on

the 2010 Chrysler Sebring and Dodge Avenger.

* Scored first place for greatest year to year JD Powers quality

improvement on the Chrysler Sebring Convertible.

* Highest FTC Suspension Alignment ranking of all Chrysler Corporation

Assembly plants.

* Currently working on 10 Major Kaizen and 17 Standard Kaizen projects.

GENERAL MOTORS CORPORATION, Warren, MI 1993-2009

Fuel and Exhaust Systems, Component Planning Analyst 2008-2009

Coordinated System Management Teams ( SMT ) consisting of Directors,

Managers, Design Engineers, Purchasing and Suppliers to schedule parts on

program plans. Created component plans for exhaust systems, heat shields,

and fuel systems on global platforms.

* Assumed responsibility for managing the plans of three former

employees.

* Monitored metrics reports and resolved and corrected plan

discrepancies for engineering centers around the world.

Chassis, Powertrain Engineering Project Engineer 2006-2008

Solved issues on fuel pump modules for global platforms. Fuel Department

Liaison for all returns at the Warranty Parts Center to initiate root

cause analysis. Managed suppliers, vehicle assembly plants and cross-

functional organizations to reduce complete fuel system warranty. Led

Managers to meet Cost Per Vehicle ( CPV ) and Incidents Per Thousand

Vehicle ( IPTV ) goals. Utilized: SWIFT, GART, QIS2.

* Reduced global fuel pump warranty issues 44% using Red-X methodologies

in 10 Months.

* Reduced Full Size Truck fuel system warranty costs 50% resulting in

best in class JD Power rating.

* Identified and solved Full Size utility low fuel handling issue in 5

months which saved $1.3 Million.

* Patented Honeycomb Flame Arrester and Flow straightener for an E-85

fuel system fill pipe.

Chassis, Powertrain Engineering Design Engineer 2003-2006

Designed, tested and released fuel tank, evaporative canister, fuel lines

and fill-pipe assemblies for: 2006-2009 Heavy Duty ( HD ) truck, 2007

Small car and 2005-2006 Premium Cross-Over car.

* Modified Tank and Fill-pipe design content to save $1.20 cost per

vehicle on 200,000 vehicles.

* Achieved zero issue production launch of the 2007 HD full size

utility.

* Utilized off-the-shelf designs for the Cadillac SRX to save piece cost

and tooling investment.

* Implemented innovative new high technology hydrocarbon containment

system on small car fuel tank to meet federal Partial Zero Emission

Vehicle requirements.

GENERAL MOTORS CORPORATION ( continued )

Issue Resolution Team ( IRT ) Leader 2001-2003

Fort Wayne Assembly Plant-Fort Wayne, IN

Issue Resolution Team Product Chairperson for assembly plants Final Line

area. Managed resolution of engineering and manufacturing vehicle build

concerns for the 2003 Full Size Truck mid-cycle enhancement ( MCE )

launch. Led full size truck engineering group managers, Red-X plant

masters and assembly operators to follow JD Power 'Issue Avoidance'

chart.

* Implemented innovative engineering, tooling and process changes which

saved capital.

* Received award for IRT to close out all issues first ( 104 total

issues ) against two other teams.

* Closed quality issues with seven GM Full-Size truck plants to reach

Ship to Commerce on time.

* Created Audit chart to track, monitor and resolve issues resulting in

achieving Consumer Reports recommended buy list.

Vehicle Assembly Plant Project Engineer, Fort Wayne Assembly Plant-Fort

Wayne, IN

Solved vehicle quality issues / problems using Shainin RED-X statistical

based engineering problem solving methods. Interfaced with Engineering

and Assembly plant to address assembly and processing issues, quality

issues, engineering tryouts, supplier quality issues.

* Created 'JD Power Project Wall' to improve Fort Wayne Assembly's

quality which resulted in having the best-in-class JD Power quality

score for a Full Size pickup assembly plant.

* Solved Fort Wayne Wheel re-balancing warranty issue.

* Coached four Shainin-GM Red-X Apprentice and Journeymen problem

solvers.

Vehicle Assembly Plant Project Engineer 1999-2001

Moraine Assembly Plant-Moraine, OH

Solved assigned vehicle quality issues and problems using Shainin RED-X

statistical based engineering problem solving methods.

. Achieved Shainin-GM RED-X Master Level Certification in just 18

months.

* Solved Vehicle automated alignment rack problem, one of top five

highly complex, repetitive and costly quality issues at Moraine

Assembly in 4.5 months.

* Saved GM $575K from solved RED-X and quality projects in Chassis,

Powertrain, Closures and Electrical systems.

Chassis and Powertrain Engineering Design Engineer 1993-1999

Pontiac, MI

Designed, tested and released 1995-2002 Small Pick-up and Utility exhaust

systems to meet global emissions and noise requirements. Designed, tested

and released 1993-1994 small truck engine mounts.

. Commonized design and assembly processing of L4 and V6 systems

resulting in $6M cost savings.

* Achieved ergonomic improvement, reduction in assembly time, part

complexity and warranty costs.

* Implemented exhaust system cabin noise reduction sufficiency plan for

1999-2000 resulting in improved customer satisfaction.

MODERN ENGINEERING SERVICE COMPANY, Dearborn, MI 1991-1993

Product Development Engineer

Responsible for noise testing and exhaust tuning for 26 exhaust

configurations 1997 Full Size Ford Vans and Chassis-Cabs.

. Co-authored SAE technical paper- Effect of forcing Worst Case Exhaust

System configuration on Ford Full size Vans and Chassis-Cabs.

TECHNICAL ENGINEERING CONSULTANTS, Auburn Hills, MI 1990-1991

Design Engineer

Designed, tested and released 1995 Chrysler Large car exhaust system.

MEGATECH ENGINEERING INC., Warren, MI 1989-1990

Design Engineer

Created, developed and manufactured hand apply park brake multiplier for

1993 Opel Mini-van.

WESTERN MICHIGAN UNIVERSITY, Kalamazoo, MI 1989-1990

Technician / Racing Crew

Created brake system for the 1990 Sun Seeker solar-electric car. Achieved

second place in the Solar-Electric Challenge Grand Prix race in Phoenix,

AZ.

EDUCATION / LICENSES

B.S., Engineering / Applied Sciences, Western Michigan University,

Kalamazoo, MI 1989

. Aviation Technology

Shainin-GM Red X Master 2001

Private Pilot License 1990

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