Manager Engineer

Name: Paul C. Wetzel, *** Louder Way, Rockwall, TX 75087

972-***-**** or 469-***-**** abnhh0@r.postjobfree.com

Education: BSME, University of Dayton (1993)

APQP CATIA SIX SIGMA

DFMEA AUTOCAD SHAININ

DESIGN CONTROL ABAQUS(FEA) SOLID EDGE

DVP&R GD&T SPC

PFMEA METROLOGY DOE/DFM

PQCT/CONTROL PLAN TS16949 LEAN MFG.

GAGE R&R/ISOPLOT ISO9001-2000 KAIZAN

Work History:

2006 – Present

Director of Operations, Design Masters

Responsibilities: Establishment and execution of business plan and budget for

company. Responsible for hiring the appropriate personnel to meet the needs of the

organization, delegation of key roles & responsibilities, and support of these individuals

in the establishment of world class business systems to ensure optimum efficiency and

profit for the organization.

Accomplishments:

Led turnaround of organization from losses in 2005 & 2006 to 25% net profit in 2007 - 2008.

1999 - 2006

Quality Assurance Manager, Yusa Corporation

Responsibilities: Lead QA department in our endeavor to provide outstanding quality to our customer. This

includes advanced quality planning, mistake proofing for claim avoidance, why-why analysis for rejects to

determine the root cause and hard countermeasures for occurrence and detection, continual conformance

product testing, process monitoring using SPC, and compliance to ISO9000-2000 standards. Yusa has sales of

over $200M/year and 1200 associates; its primary customer is Honda. Direct reports include 1 Asst. Mgr. and 4

Coordinators as part of the QA organization which includes a total of 50 associates. Yusa manufactures

vibration isolation rubber products such as engine mounts (block and hydromount), suspension bushings,

dynamic dampers, as well as other rubber products. Manufacturing processes include rubber mixing, metal

parkerization & prep. for rubber adhesion, rubber molding and extrusion, shrink and grind, hydromount

assembly, and finish paint.

Accomplishments:

Reduction in quality claims & index by over 80% over the past two fiscal years.

Reduced internal reject costs by over $150,000/month. (50% reduction)

Reduced sorting costs by $80,000/month. (75% reduction)

Research & Development Manager, Yusa Corporation (OH)

Responsibilities: Directed R&D department in the design and development of elastomeric vibration isolation

parts (engine mounts, suspension bushings, dynamic dampers, etc.) for Honda and non-Honda vehicle

applications. Direct reports included 5 Coordinators as part of the R&D organization which included 15

members. R&D budget surpassed $2M annually.

Accomplishments:

Developed Design Control procedure to successfully develop a part & process from concept to M/P. This

procedure shows what needs to be done when and by whom. This cross-functional matrix has been adopted

as the standard for new model development.

Implemented Design Review system to ensure proper maturation from concept to prototype to pilot to M/P.

Instituted a Design Change procedure and format in compliance with ISO.

As LPL (Lead project leader), successfully launched the 2003 Accord(55 new parts) by meeting the very

aggressive goals of 100% product validation prior to launch and by reducing the quality claim/index spike

associated with the new model launch by 50% over previous models.

Provided vision & leadership to grow Yusa’s development department from 5 members to 15 in four years

and to go from being dependant on Japan for design to being able to be completely independent. This

direction has placed Yusa in the position where they will be breaking ground this year on a new R&D

technical center.

1997 - 1999

Program Manager, Ochs Industries

Responsibilities: Managed various new model programs for Compaq and Intel in our supply of computer

chassis components, computer assemblies, and network hub/router system assemblies. Ochs employed around

150 associates, but is no longer in business.

Accomplishments:

Implemented New Model system to ensure proper part/process maturation in accordance with customer

timing requirements.

Implemented Design Change system in accordance with QS9000.

1993 - 1997

Senior Product Design Engineer, Chrysler Corporation

Responsibilities: Design and development of various parts including plate-fin evaporators, vapor canisters, and

pcv valves. I served as launch manager for the ’94 Camry, ’95 Cirrus, ’96 Minivan, & ’98 Intrepid/Concord

vehicle from conception to product acceptance, sign-off, and launch. Additionally, I supervised the R&D lab

which performed various climate control and emission testing for all of our products which included

evaporators, radiators, heater cores, HVAC assy., ECM, vapor canisters, & pcv valves. DTP had over 2000

associates. Direct reports included 10 lab technicians.

Accomplishments:

Promoted 2 times in four year period

Product Design Engineer 1994-1996

Resident Engineer 1993-1994

Earned the highest rating, “ROLE MODEL” for three straight yearly performance reviews.

Recipient of the Chrysler Employee Recognition Award in my first year for my efforts in the successful

launch of the ’94 Camry vapor canister.

Led the successful launch of new corrosion prohibitive aluminum alloy that extends the life of the

evaporator by more than 300%. This has resulted in warranty savings for Chrysler of $75M per year. From

the drawing board to production took only 9 months.

Conceptualized, designed, and led the launch of the “one-piece” pcv valve: this valve solved a quality issue

in the field and saved Chrysler $400,000 per model year. From conceptualization to launch took only 15

months.

Successfully designed a new evaporator plate, using CFD & rapid prototyping as modeling tools, that

launched in 1999 that eliminates the acoustic resonance (whistle) within the evaporator.

Directed efforts that improved evaporator FTC from 55% to 75%, pcv valve FTC from 70% to 99%, and

vapor canister FTC from 85% to 98% in less than one year.

Successfully received design and process sign-off and launched the ’94 Toyota vapor canister three months

ahead of schedule, and led efforts that earned our plant a Supplier Quality award from Toyota.

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