GERALD THOMAS MULKA, JR.

**** ****** ****** ** ( Kentwood, Michigan 49546

616-***-**** ( abmzaf@r.postjobfree.com

ENGINEERING / PROJECT MANAGEMENT

Accomplished project manager with credentials & proven experience devising

and implementing solutions that improve production efficiency and product

quality. Analytical thinker, proficient in guiding initiatives to

streamline manufacturing operations and processes. Innovative problem

solver; can quickly troubleshoot and resolve vital equipment issues and

operational deficiencies. Critical change agent and skilled team leader;

adept at cultivating strong relationships enterprise-wide and at managing

concurrent projects to fulfill deliverable and milestone commitments.

Manufacturing Operations ( Strategic Planning ( Goal Alignment ( Business

Analysis ( Budget Management

Project Management ( Policy Development ( Specification Development ( Team

Leadership ( Mentoring

Quality Methodologies ( Safety & Quality Programs ( Process Automation &

Innovation ( Communications

PROFESSIONAL EXPERIENCE

BENTELER AUTOMOTIVE, Grand Rapids, Michigan ( 1992-2009

Teir-1 OEM of automotive structures, systems, and components with $3B in

annual revenue.

Contract Engineering Consultant 1992-1994

Manufacturing Engineer 1994-1998

Senior Manufacturing Engineer 1998-2000

Senior Project Engineer 2000-2009

Senior Project Engineer (2000-2009)

Lead cross-functional teams in all facets of production and quality

engineering initiatives. Identify and prioritize improvement opportunities.

Devised creative solution concepts, develop project specifications, and

defined capital costs, with benefits & justification analysis. Incorporate

proven quality principles, such as Kaizen, Lean, and TQM, to streamline or

overhaul existing processes. Manage and execute engineering change as well

as technology and equipment procurement appropriations. Administer formal

process documentation. Present reports to executive staff regarding project

status and quality performance metrics. Evaluate vendors and product

offerings to select sourcing partners. Train and mentor team members.

. Coordinated activities and resolved concerns for concurrent projects at

multiple facilities.

. Delivered more than $500K in annual cost savings by supplanting obsolete

robotic work centers with cutting-edge hybrid automated cell. Reduced

manual labor requirements and increased production yield and quality,

facilitating ~35% improvement in bottom-line profits.

. Attained ~2.5-fold improvement in manufacturing capacity with unchanged

production footprint by devising and deploying Simplified Weld Cells.

Catapulted plant to #2 in production-per-square foot among all corporate

facilities worldwide.

. Drove incremental enhancements to welding and production operations with

implementation of laser target system for machine operators as well as

customized torch holder for automated welding applications.

. Instituted detailed training and operations manual that established

machine standards, setup and tooling guidelines and standardized work

outlines. Resulted in substantial rework as well as down time savings

for each work center setup and changeover schedules.

. Conducted multiple lean events to improve ongoing customer product lines

& new product launches:

- Production improvement of 25% for Toyota 044L door beam work

center...

- Line balance & weekend O.T. elimination of Nissan spot weld

work center...

- Mazda Bumper work center flow improvement & imbalance

elimination...

- Reverse engineer & D.O.E. of Toyota tube swedge program...

- Developed standardized work for new work centers deployed

throughout plant...

GERALD THOMAS MULKA, JR. ( Page Two ( abmzaf@r.postjobfree.com

Manufacturing / Senior Manufacturing Engineer (1994-

2000)

Support of manufacturing equipment and processes to ensure quality

production goals for plant wide SQCDM metrics. Compiled data and assessed

performance reports to identify and remedy process deficiencies; leveraged

quality methodologies to automate and streamline production activities.

Devised comprehensive project plans complete with scope, milestones,

budgets, and key deliverables.

Investigated cutting-edge tools and equipment to recommend production and

process strategies. Prepared cost-benefit analyses for capital

expenditures. Developed solution prototypes as well as formal process

documentation with weekly staff report presentations.

. Started as Consulting Engineer with contract through CDI Services, Inc.

Recruited to senior-level, in-house engineering position in 1992.

. Commissioned to develop and deploy unique SIMPLIFIED WELD CELL to enable

expansion of business volume without facility investment and meet world

class FTTQ customer requirements.

. Slashed rework rate by 10% by modifying key assembly component for Ford

Escort product to enhance fit and welding processes.

. Developed unique torch function package that simulated robotic solution

but at 75% less cost; honored with President's Award for innovation and

productivity impact.

. Developed & instituted Tooling Repair Order (TRO) document to record and

manage facility weld fixtures and gauges.

. Supported 90% MIG and 10% Resistance welding lines which produced over

100K finished MIG welded assemblies. Each assembly required a minimum

of (4) 25-mm MIG welds. Over 400K MIG welds were produced each day. All

assemblies were produced on a either robotic or automated MIG weld work

stations...

ADDITIONAL EXPERIENCE:

TROY TECHNICAL SERVICES, INC., Grand Rapids, Michigan 1990-1992

Design & Project Engineer (Special Machines & Tooling)

GWI ENGINEERING, INC., Grand Rapids, Michigan 1989-

1990

Design & Project Engineer (Robotic Resistance Transguns & Equipment)

MCDONNELL DOUGLAS (Contract), Grand Rapids, Michigan 1987-1990

Design Engineer (Flight Controls For C-17 Military Transport Aircraft)

NEWCOR, INC., Bay City, Michigan 1984-1987

Detailer & Designer (Resistance & Robotic Weld Equipment & Tooling)

EDUCATION:

Bachelor of Science in Mechanical Engineering 1983

Lake Superior State University, Sault Ste. Marie, Michigan (Dean's List)

Statistical Process Control & Geometric Tolerance Certificates

1986

Delta College, Bay City, Michigan

Failure Mode & Effects Analysis (FMEA) Certificate 1995

Indiana University South Bend, South Bend, Indiana

PROFESSIONAL DEVELOPMENT: 1996-2008

Total Quality Management (TQM)

Problem Solving for Engineering Managers Effective Leadership Training

Kepner Trego Problem Solving Analysis

Lean Six Sigma Tools (Kaizen, 5S, FEMA, Poka-Yoke,

Ect

Dale Carnegie Leadership Training for Managers

GERALD THOMAS MULKA, JR.

3611 Burton Street SE ( Kentwood, Michigan 49546

616-***-**** ( abmzaf@r.postjobfree.com

Dear Sir/Dear Madam:

Having guided teams in all aspects of manufacturing and quality improvement

projects, I am proud to have played an instrumental role in the success of

various organizations such as Benteler Automotive. As a creative and

resourceful engineering manager with a strong history of effective

leadership, I understand and possess the business savvy and the management

attributes necessary to direct mission-critical projects and programs. I

look forward to the opportunity of leveraging these talents and more as

your next Engineering and R&D Leader.

My strengths range from strategic planning and team leadership to solution

design and implementation. Highlights of my qualifications include:

. Leveraging proven manufacturing methodologies like Kaizen, Lean, and

Total Quality Management to streamline operations, drive automation &

productivity, to improve product quality.

. Crafting and instituting robust operational policies, procedures, and

best practices to ensure that strict standards and expectations were in

place for design, engineering, and manufacturing teams to surpass

objectives for machine setup and changeover as well as rework.

. Devising innovative components and systems that slash production times

and increase capacity within the same space constraints, including

development of Simplified Weld Cells that boosted weekly yields from 185K

units to over 400K units.

. Earning corporate President's Awards for effective team leadership,

process innovation, and profit improvement.

For a more detailed presentation of my skills and background, please review

the enclosed resume and feel free to contact me at your earliest

convenience. Thank you in advance for your consideration, and I look

forward to your call.

Sincerely,

Gerald Thomas Mulka, Jr.

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