Project Manager Engineer

Brian Klear

*** ***** ***** ****** • Brighton, MI 48116 • 810-***-**** • *******@*********.***

Project Management and Manufacturing Professional

Versatile, results oriented project manager with 20+ years of broad manufacturing and engineering

experience. Self motivated with a strong ability to lead a global team. Detail oriented with highly

developed administrative and analytical skills shown through meticulous documentation and

organization. A problem solver who tackles challenges head on with professionalism and integrity.

Program management Injection molding Automation

PMP certification pending Plastics decorating and assembly Polyurethane RIM

Lean manufacturing IML (in mold labeling) Final trim assembly

Consumer packaging Engine machining and assembly Transmission machining

Automotive interior trim Automotive glass fabrication Iron foundry

Program Management Experience Highlights

Managed an international team of engineers and tooling suppliers for an IML container and hinged

lid. Successfully delivered Asian tooling and European automation and labels, installed in the US

manufacturing facility on time and below $3MM budget. Full responsibility for scope, budget, timing,

communication, risk and actions.

Led multiple cross functional teams for launch of numerous automotive instrument cluster and

interior trim components and assemblies. Coordinated tooling, automation, engineering and

customer requirements for injection molding, decorating, painting, plating and assembly. Wide

variety of program complexity, with simultaneous and overlapping projects supplying many major

Tier 1-2 suppliers for all major OEM’s.

Successfully integrated manufacturing facilities in US and Mexico with customers and suppliers

spread across US, Mexico, Asia and Europe, inspiring team dynamics for complex international and

domestic projects from a remote home office.

Automation and Tooling Experience Highlights

Procured multi-cavity IML automation cell, including concept, RFQ and quoting, through pilot and

production system design review, build and FAT. First of two $1MM production cells achieved

production rate by the 3rd day of a planned 4 week launch ramp.

Key player in design of a high speed continuous motion automation system for a high volume

aerosol actuator assembly. System throughput 160MM pieces/year. Multiple systems planned

globally.

Directed design and build of a semi-automated assembly cell for an automotive radio/HVAC bezel

assembly with 3 unique versions containing 40+ components. Innovative $1MM+ lean manufacturing

cell included multiple SCARA robots, machine vision inspection and some manual stations. Project

launched on time and under budget.

Drove installation and launch of all machining center automation for a fully automated US engine

machining plant, including gantry robots, conveyors, palletizing and pallet handling. Designated point

person for open issue reporting and resolution for on time launch.

Devised an innovative, advanced robotic manufacturing process to eliminate a hazardous chemical

exposure situation. Succeeded in replacing hand held chemical applicators for 80% labor reduction,

60% material reduction, and elimination of constant chemical exposure.

Brian Klear

Page Two

Manufacturing Engineering Experience Highlights

Integral team member in an engineering field office at a US automotive transmission plant

undergoing a major equipment and capacity upgrade that included 600 new machining centers.

Designed plant layouts and installation plans for multiple machining lines of various complexities.

Identified and eliminated the root cause of a contamination issue that was causing a catastrophic

90% scrap rate. Guided a cross functional team to deftly utilize Dorian Shainin DOE techniques in a

14 variable experiment. Patience and strict adherence to statistical principles resulted in complete

elimination of the defect after an extremely stressful period.

Supervised installation and startup of automated manufacturing equipment in new facilities in US and

Europe. Regular travel to startup site from installation through production ramp.

Performed a detailed material flow analysis of headliners and returnable racks in a US auto assembly

facility. Utilized field study, plant layout and comprehensive spreadsheet analysis to implement lean

manufacturing principles to successfully reduce material handling costs for headliners by 30% with

less than 1 year payback for the facility improvements.

Employment History

NYPRO, INC. • Clinton, MA • Manufacturer of injection molded / decorated / assembled components.

Sr. Program Manager • 2004-2009

KEY PLASTICS, LLC • Northville, MI • Tier 2-3 supplier of injection molded automotive trim.

Project Manager • 2002-2004

GHAFARI ASSOCIATES, LLC • Dearborn, MI • Architects, Planners, Engineers, Managers.

Sr. Manufacturing Engineer • 2000-2002

KEY PLASTICS, LLC • Northville, MI

Project Engineer • 2000

Secondary Tooling Engineer • 1998-2000

SSOE, INC. • Toledo, OH • Engineers, Architects.

Sr. Industrial Engineer • 1995-1997

GUARDIAN INDUSTRIES CORPORATION • Auburn, IN • Supplier of automotive glass.

Product Engineer • 1991-1995

Process Engineer • 1988-1991

GENERAL MOTORS CORPORATION • Defiance, OH • Supplier of automotive iron castings.

Central Foundry Division (now Powertrain Division).

Quality Supervisor • 1988

Manufacturing Engineer • 1987

Production Supervisor • 1986

Various Student Assignments • 1983-1985

Education

VILLANOVA UNIVERSITY • Philadelphia, PA

Masters Certificate in Project Management • Expected April, 2010

PMP: Eligible to sit for PMP Exam • April, 2010.

Lean Six Sigma Green Belt Certification • Expected June, 2010.

GMI ENGINEERING AND MANAGEMENT INSTITUTE (now KETTERING UNIVERSITY) • Flint, MI

Bachelor of Science in Industrial Engineering • 1988

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