Project Manager Engineer

***** ********** *****, ******, ** *****

586-***-**** (home)

email: ************@*****.***

OBJECTIVE

Technical leadership position in a firm to which I can directly contribute

value through innovative design, production and business solutions, and

from which I can learn and expand my experience.

CAREER SUMMARY

Energetic technical leader with a broad business and a practical hands-on

understanding due to education and experience, who seeks first to

understand and then envisions and implements innovative methods, systems

and solutions; who believes in doing the job right the first time instead

of taking short cuts.

EDUCATION (combination of technical and business degrees)

Master of Business Administration (MBA): Emphases: Operations and Finance.

Graduated High Distinction; top 10% of class; 72 semester hours, Brigham

Young University (BYU), April 1983.

Bachelor of Science (BS): Major: Manufacturing technology processes and

tools. Graduated Magna cum Laude 3.9/4.0 GPA; 142 semester hours, Brigham

Young University (BYU), April 1980.

Major German Language Diploma (GDS): Documents native-like level of German

language proficiency. Goethe Institute in Frankfurt and Ludwig-Maximilians-

University, Munich, Germany, Nov 2000.

ACCOMPLISHMENTS OVERVIEW (see also Experience Detail below)

- Reduced investment and cost per unit produced through innovative

manufacturing plant design for all new assembly plants.

- Improved company competitiveness through strategic global business

analysis and recommendations.

- Improved international product program management through development of

engineering business processes between international business units,

product prototype build management and product testing evaluation.

Removed program road blocks through negotiation with executives on

international product program issues.

- Introduced major new product smoothly through manufacturing engineering

and industrial engineering team supervision and through engineering work

on the assembly plant process, time studies and material, tools and

equipment layout development.

- Improved quality and ergonomics in the assembly process through assembly

process analysis, ergonomic engineering and through development of a good

working relationship with the union.

- Brought systems on-time from concept to production for an all new major

product in a new start-up company (Saturn) through business process

development, program planning, budget management, supplier management,

system engineering and manufacturing engineering.

- Executed smoothly and on-time a new vehicle system for a high volume

product, in a high visibility rush program through close supplier

engineering management and assembly plant process development.

- Reduced risk and enhanced company acquisition decision process with

financial discounted cash flow analysis.

- Improved understanding of competitive position in the industry with

technical cost model development and manufacturing cost analysis of

industry competitors.

EXPERIENCE OVERVIEW (see also Experience Detail below)

- Project manager: Global engineering team to redesign the entire general

assembly plant for all future GM plants worldwide.

- Project team manager: GM Research, Massachusetts Institute of technology

(MIT) and multi-discipline engineering project team to develop a complex

technical cost model to evaluate new general assembly plant designs.

- Project engineering team leader for new international vehicle programs.

- Management consultant and researcher, financial analyst (McKinsey & Co.

Inc).

- Strategic global initiative and competitive analysis consultant.

- Manufacturing engineering project manager for new vehicle programs.

- Product engineer for future program fuel system, power train mounts.

- Supplier quality engineer including supplier selection and management.

- Plant manufacturing engineer, industrial engineer and engineering

supervisor.

- Manufacturing technology research and development engineer (aerospace

material machining and robotics).

- Test engineer (fuel system, entire vehicle).

- German- English technical translator of automotive body shop and general

assembly specifications.

EXPERIENCE DETAIL (see also http://www.linkedin.com/in/tomcoyne )

German-English Engineering Translator; KUKA Systems North America, Sterling

Heights, MI. Dec 2008 - Feb 2010

Produced complete high quality illustrated translations of automotive body

shop and general assembly technical specifications and drawings for new

vehicle programs (more than 335,000 words in total).

General Assembly Project Manager, Manufacturing Engineering (ME) Manager

and Business Strategy Consultant; General Motors Corp. (GM), Warren, MI.

2001 - Nov 2008)

- Led global development of next generation general assembly plant layout,

including selling executives on the project, creation of the vehicle

assembly technical concept and complete redesign of the plant. Led a GM

Research, MIT and multi-discipline engineering team to develop a complex

technical cost model to evaluate plant design alternatives. The new

layout incorporates building design features, major manufacturing

equipment, conveyors, assembly process and advanced lean process

supporting materials layout and lean production principles from Toyota.

The new layout is the basis for all new GM assembly plants worldwide.

- Analyzed the major competitors and recommended to senior executive

leadership the basis for the GM strategic globalization effort as

implemented since 2003, and an expansion of the scope of production in

Russia. Conducted analysis to support the selection of target production

locations in Eastern Europe.

- Created strategic policy analyses used in the formulation of the US Dept

of Commerce Manufacturing Policy

- Developed and applied global assembly and business process standards and

facilitated the globalization of the general assembly ME and the

strategic manufacturing competitive analysis organizations.

- Analyzed technical and financial impact to multiple general assembly

plants of new vehicle programs and planned the production of the new

vehicles.

Foreign Assignment - Project Manager, Mfg. Engr. Manager, Product Engr.

(PE) Manager and Test Engineer, GM Europe (OPEL) in Germany, 1996-2001.

- Developed and administered the new product production acceptance process

between GM Europe PE and GMNA ME in order to influence vehicle system

designs to accommodate assembly plant requirements

- Managed prototype builds for GMNA to meet build content, schedule

requirements and buildability evaluations.

- Identified and communicated to GMNA significant vehicle test events

affecting the new vehicle development program in order to assure proper

engineering response.

- Negotiated agreements and resolved disputes between GMNA and GM Europe

executive leadership about experimental vehicles and parts acquisition

requirements, vehicle test requirements, build schedule and issues.

- Negotiated and developed and managed part and vehicle procurement,

shipping and financing processes

- Assisted visiting US based engineers in dealing with cultural and

language differences and developed the solution for their legal concerns

with German Immigrations authorities.

- Translated technical and legal documents and served as language

interpreter for technical events.

Assembly Plant General Assembly ME and Industrial Engineering Supervisor,

GM-SATURN Corp., Spring Hill, TN, 1992-1996.

- Developed the assembly process, manpower requirements, tooling and

equipment for new model launches in high volume production, supervised a

plant engineering team.

- Worked with UAW union representatives for improved labor efficiencies

with new product introduction.

- Modified the assembly process and implemented tooling to improve

efficiency, and to resolve assembly problems and ergonomic problems.

General Assembly ME Supervisor, Product Engineer, Supplier Quality Engineer

(SQE), GM-SATURN Corp., Troy, MI. 1985-1992.

- Developed chassis department business processes for a new company

(SATURN)

- Created product planning structure (critical path planning) and executed

it from concept to high volume production with both internal and chassis

supplier organizations.

- Developed and modified system designs and technical specifications,

created the assembly plant process for the new parts, evaluated internal

test results, coordinated product changes with other vehicle systems and

with the assembly plant, released parts and systems to production.

- Supervised reporting engineers as they executed their plans with

suppliers, internal engineering, purchasing and assembly process

engineering.

- Selected suppliers, communicated production requirements to suppliers and

assured adherence, managed supplier part development process, evaluated

suppliers' part designs, tooling and fixtures, statistically analyzed

production and test data, granted design deviations and production

acceptance to suppliers, worked with suppliers to solve part production

problems and determined how deviating parts should be dispensed.

- Administered annual prototype parts and tools budgets ($ millions).

Research Consultant, McKinsey & Co., Inc., Cleveland, OH office 1983-1985.

- Created a discounted cash flow model based upon financial data to

determine an acceptable offering price range for a major corporate

acquisition by a consumer goods client.

- Built technical cost model and wrote computer program to analyze

competitive cost position for major steel producers using manufacturing

process formulae.

- Identified cost reduction opportunities in the transition from product

development to manufacturing process for a medical products client.

Manufacturing Technology Engineer, Northrop Corp., Aircraft Division,

Hawthorne, CA, 1980-1982.

- Led proposal writing team and wrote major part of winning contract

proposal to USAF for Flexible Manufacturing System (FMS) study.

- Led Northrop and diverse subcontractor team in developing risk analysis

methodology for FMS.

- Developed robotic fixtures and air-logic controlled smart end-effector

for aluminum aircraft panel milling and drilling operations.

- Conducted original drilling research on aircraft grade titanium sheet

metal for aircraft production process development.

EDUCATIONAL AWARDS

Beta Gamma Sigma Honor Society - elected 1983;

Phi Kappa Phi Honor Society - elected 1980;

MBA Dean's List 1981-1983;

National Dean's List 1982-1983;

College of Engineering & Technology Dean's List 7 of 8 semesters;

Undergraduate & graduate school academic scholarships

REFERENCES (see also http://www.linkedin.com/in/tomcoyne )

Available upon request

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