Daniel John Universal

*** ********* ***, *********, **, 39157-5187

601-***-**** ( home ) / 601-***-**** ( mobile )

abl9jm@r.postjobfree.com

SUMMARY & Highly motivated results-orientated professional with a

successful history in manufacturing process

OBJECTIVE design, operations management, problem solving &

continuous improvement. Demonstrates strong

leadership qualities, communication, organizational & team

building skills. Sixteen years experience

w/automotive OEM's. Seeking an Executive-Level Director

of Manufacturing, Engineering or Plant

Manager Position in Operations; offering innovation,

personal growth, challenge and responsibility.

PROFESSIONAL NISSAN RENAULT CORPORATION - VEHICLE ASSEMBLY OPERATIONS

Canton, MS

EXPERIENCE Position: Senior Product Quality Manager ( Inspection /

Pre Delivery / Lab Investigations )

10/09-present Duties: - Created a comprehensive plan

based on Consumer Reports & internal evaluation

audits that focused on Problem Solving,

Change Management, Process Capability

& Quality Management Systems with customer

satisfaction being the #1 priority.

- Facility awarded J.D. Power and Associates

2009 Initial Quality Study ( Altima )

- Decreased warranty @ 3MIS from 11.2 to 9.8

PPH [ 1MIS from 5.3 to 4.7 PPH ]

- Utilized mutilation team & disciplined

quality gates to contain defects in station.

- Monitored quality variation control

characteristics ( HVAC fluid volumes, brake

function, vehicle pull, tire vibration, wind noise, closure efforts ) for

capability &

trend. Audited job observation process to

ensure standardized work is occurring.

- Worked w/Supply Chain Management to improve

on-time delivery performance.

Analyzed value stream maps to optimize

vehicle flow, purchased tracking system

& cross trained repair techs which minimized

lead time while increasing DSTAR.

01/07-10/09 Position: Senior Manufacturing Operations Manager ( Trim

/ Chassis / Final Assembly )

Duties: - Reported to Director of Manufacturing.

Accountable for (6) mid-level managers,

(38) supervisors & (685) technicians.

Achieved and sustained department KPI's.

- Developed a business plan ( road map ); set

objectives, targets, strategies, control

items & tracking mechanisms. Communicated

to employees, obtained their input

& commitment, towards a common goal. Made

decisions, considered immediate

& long-term implications, benefits & costs,

and risks associated with alternatives.

- Strengthened management safety culture.

Lowered Incident, Recordable & Lost

Time rates by 46%. Measured audit

effectiveness. Set-up ergonomic job rotation.

- Added poka-yokes to prevent "flow-out",

removed non-torque controlled battery

& pneumatic tools, installed DC electric

guns, interlocked with conveyor for ALS

- Used Automatic Guided Vehicles, low cost

automation & Block Kitting concepts

to improve efficiency. Benefits realized;

minimized waste, increased value added

work content, removed (36) direct labor

heads, reduced decision making process,

simplified rebalance complexity, improved

part presentation & material handling.

- Raised plant cost competitiveness level

through DSTR & CPU reductions. Pulled

out fixed heads, trapped labor & over speed.

Re-allocated elements, saved $3M.

- Mitigated constraints to attain scheduled

delivery commitments. Department had

been missing build by 800 vehicles a month.

Boosted revenue by $32M a month.

- Mentored, supported & motivated high

potential team members. Hired/promoted

staff as required. Taught Emotional

Intelligence & Situational Leadership vision.

- Selected to participate in global CFT,

challenged VP's on policies & procedures.

Proposals submitted; capacity utilization /

volume flexibility, equipment sourcing

options, new model budget setting & over

specification as it relates to high costs.

DAIMLER CHRYSLER CORPORATION - MANUFACTURING OPERATIONS

Detroit, MI

02/04-01/07 Position: Production Superintendent ( Case Carrier

Machining / Warren Truck Assembly )

Duties: - Applied Lean Manufacturing Principles

in safely producing high quality, on time

products to meet customer and profitability

expectations. Established production

metrics & performance standards for a staff

of (9) supervisors & (242) associates.

- Trained & certified Shainin Red X Journeyman

( Master Black Belt ). Leveraged

Toolbox ( Pareto, Isoplot, Strategy Diagram,

Multi-Vari, Concentration Diagram,

BOB/WOW, Tolerance Parallelogram ) to

converge on source of variation; scrap

decreased by $3.75M in 2004. Projects

concluded; thrust face & spherical radius.

- Identified bottlenecks that constrained

throughput, formed problem solving team,

planned & prioritized work w/PDCA's,

allocated resources, JPH jumped by 30%.

- Determined optimal buffer space b/w

operations so process can continue without

being blocked or starved. Balanced

tradeoff b/w costs for buffers and increased

WIP vs benefits of additional throughput due

to decoupling on retooled WK line.

- Integrated 5-S principles into daily

requirements, thereby providing a safe, clean,

efficient arrangement where tools, equipment

& material have a specific location.

- Benchmarked use of visual management such as

standardized work displays, foot

printing & scoreboards to identify

abnormalities which required corrective action

- Spearheaded small team concept of job

rotation & shared roles / responsibilities,

this reduced effects of absenteeism &

enhanced morale via operator involvement.

- Employed "bank of 1"strategy to reduce

nonconforming parts & verified w/LPA.

03/03-02/04 Position: Senior Manufacturing Engineering Manager (

Rear Differential / Axle Assembly )

Duties: - Managed Engineering Operations at

Detroit Axle Plant with Responsibilities for

Safety, Quality, Delivery, Cost & Morale.

Led, coached & supervised team of (8)

Process, Electrical and Plant Facility

personnel that exceeded departmental goals.

- Supported program management of 2004 HB &

2005 ND launch by coordinating

design, build & approval of machining

equipment, fixtures, gages & cutting tools.

- Trained & certified as Shainin Red X

Apprentice ( Green Belt ). Using this data

driven problem-solving approach, we

minimized departmental scrap cost by $1.4

million in 2003. Projects concluded;

oversized bores, thin flanges & shaft length.

- Introduced & modernized tooling, which

resulted in a cost reduction of $800K in

2003. This included; HSS & carbide drills,

CBN / PCD inserts & milling cutters.

- Eliminated (21) heads through process

improvements, layout rearrangements and

additional automation resulting in a total

cost reduction of $2.85 million in 2003.

- Increased Direct Run FTC, by designing error

and mistake proofing features into

products & processes, which provided Built-

In-Quality and decreased plant PPH.

- Used Kepner Tregoe Problem Analysis Tools to

resolve special cause deviations.

07/00-03/03 Position: Maintenance Superintendent ( Mack Engine Plant

- Crankshafts / Cylinder Heads )

Duties: - Facilitated, directed & trained (6)

supervisors and (128) skilled trades. Obtained

maximum utilization of people and equipment

engaged in 3.7L Engine Assembly

to conform with vehicle quality standards,

scheduled volume and budgeted costs.

- Utilized OEE, MTTR and MTBF data to develop

& implement a TPM program.

Initiated zero breakdown Kaizen activities

such as Vibration & Infrared Analysis.

- Created an environment where communication &

trust is conducive to improved

job satisfaction. Encouraged participation

in MQAS & PQI to assist in that goal.

- Provided detailed line-ups of weekly

maintenance activities and follow-up issues.

- Procured OEM supplier services & obtained

replacement/spare parts as required.

FORD MOTOR COMPANY - POWERTRAIN & CHASSIS OPERATIONS

Sterling Hgts, MI

05/96-07/00 Position: Manufacturing Process / Tooling Engineer (

Ring and Pinion Gears / Axle Shafts )

Duties: - Worked with Product & Manufacturing

Engineering, Suppliers and New Model

Groups to estimate, design, develop and

launch Facilities and Tooling to support

product design changes, platform capacity

expansions & future vehicle programs.

- Completed PN-96, UN-93 & FN-145 Facilities /

Tooling Cost & Timing Studies.

Evaluated part design at concept stage to

resolve manufacturing feasibility issues.

- Purchased $95M in new equipment from APN

phase through runoff / installation.

- Reviewed equipment specifications for

safety, capability, reliability & durability.

- Acquired; CNC mills & lathes, spline

rollers, induction hardeners, straighteners,

drills, grinders, polishers, washers, stud

presses, conveyors, o/h gantries & robots

- Launched highly flexible lean mfg. systems &

focused on process driven product

design, process quickly retooled by using

CNC to adjust fixtures / tailstock cntrs.

- Conducted gage development and purchased

gages for all New Model Programs.

- Limited past things-gone-wrong by developing

PFMEA's that meet design intent.

- Coordinated skilled trades in the

installation of new equipment during set-up and

launch. Established training matrix for

production personnel. Stocked spare parts.

- Implemented a Quality Control plan per APQP

guidelines for Axle Shaft & Gear

Business Units. This included; Process

Illustrations, Control and Reaction Plans,

Repair and Acceptance Standards, Process

Flow Diagrams and Operation Sheets.

- Verified supplier's quality processes have

been executed via PPAP submission &

production processes are capable of

producing quality parts in sufficient quantity.

- Researched, wrote & implemented cost savings

projects which eliminated $25M.

- Reduced processing lead time by eliminating

waste & non-value added activities.

- Improved machine reliability & uptime by

preventing problems from reoccurring

via 5-why root cause analysis, thus

identifying & eliminating repetitive problems.

01/94-05/96 Position: Product Design Engineer ( 4.6L SOHC 90-Degree

V8 Rear Engine Development )

Duties: - Designed, developed, tested and

released engine components for Cost, Quality &

Performance specifications. Worked with

Corporate Vehicle Platform Engineers

in development of DOE's that optimized fuel

economy & emissions requirements

- Completed structural dynamic FEA

calculations on engine components to ensure

they were light enough to keep vehicle wght

down, yet capable of handling loads.

- Collaborated with NVH groups to isolate

mechanical vibrations thereby reducing

structural noise through implementation of

enhanced materials to absorb energy.

- Optimized valve & plug locations for airflow

and combustion using CFD models.

- Participated with Reliability and Durability

Engineers to correct Warranty issues

related to EPUS, C/100 & P/$10K @ 12 MIS.

Developed corrective action plans.

- Investigated cost reduction design proposals

for current MY production engines.

EDUCATION STATE UNIVERSITY OF NEW YORK AT BUFFALO ( S.U.N.Y. BUFFALO

) Amherst, NY

08/86-12/93 Master of Science, Engineering Management - Production

Systems, September 1993, GPA 3.25/4.0.

Bachelor of Science, Manufacturing Engineering (

Industrial/Mechanical ), May 1991, GPA 3.0/4.0.

COMPUTER Operat. Systems: - Windows XP, Mac OS X, Linux

EXPERIENCE Software: - AutoCAD, Minitab, MS ( Excel, Word,

PowerPoint, Access, Project and Visio )

TECHNICAL CNC Programming, " Turn G Code " ( GE Fanuc ); Power Mate

D Servo and Spindle Maintenance

TRAINING ( GE Fanuc ); Industrial Hydraulics ( Vickers );

Industrial Pneumatics ( Rexroth ); Machine Tool

Turret Technology ( Sauter ); Lubrication Systems ( Trabon

); Robot Programming ( ABB ); High

Speed Spindle Bearing Technology ( NSK ); Modicon PLC

Programming ( Square D ); Machining

Principles & Cutting Tool Technology ( Carboloy ); GD&T

Principles ( Meadows );

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