Engineer Project Manager

JOHN R. LEMERT

Post Office Box **** *******@***.***

Fort Wayne, Indiana 46898 260-***-****

Highly motivated leader with over 20 years experience in engineering program/project management in an industrial /

manufacturing operations role. Has particular expertise in management of successful new product introduction from

design concept, value engineering through full-scale production rates employing lean manufacturing concepts.

Possess excellent organizational and public speaking skills, and experienced in high-volume production OEM

automotive industry, metal fabrication, electronics manufacturing and injection molding/blow-molding applications.

PRODUCT EXPERIENCE

Consumer Products (Child Toy & Recreation) Snack & Entrée Food Processing & Packaging

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Military Electronics (Secure Telecom & EWS) Medical Therapy Products / Rehab Systems

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Automotive Components & OEM Subsystems Heavy Duty Truck Electrical Wire Harnesses

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TECHNICAL EXPERIENCE

Manufacturing/Assembly Process Documents Lean Methods / Continuous Improvement

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BOMs, Work Instructions Flowcharts & Routings Design & Process FMEA

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Design for Manufacture / Assembly (DFM / DFA) Manufacturing Data Collection

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Plant and Workstation Layout Tooling/Fixture Design

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Capital Expenditure Justifications Develop & Deliver Technical Seminars

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Statistical Process Control Time Study / Work Measurement Study

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Kan-Ban / Just-In-Time (JIT) Manufacturing Manufacturing Resource Planning (MRP / ERP)

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EHS & OSHA Compliance Programs ISO 9000:2000 / ISO 13485 Certifications

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Geometric Dimensioning & Tolerances (G/D&T) QS9000 PPAP Submission Qualification

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Q-1 Initial Sample Warrant (ISW) Procedures Capital Project Management

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EDUCATION

Bachelor of Science Industrial Engineering Masters in Business Administration (MBA)

Purdue University May 1984 Indiana Wesleyan University May 2001

WORK HISTORY AND ACCOMPLISHMENTS

Ferno-Washington Inc. / Angola Division – Manager, Engineering & Quality (05/2007 – 10/2008)

Reporting to the General Manager, Medical Therapy Pool Products Division

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Responsible for engineering management tasks for the development, design and launch of next-generation, PLC-

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based hydro-therapy treadmill system for post-surgical orthopedic rehabilitation for human and veterinary markets

Customer technical liaison for custom medical therapy pool projects for major rehabilitation hospital, professional

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sports, and athletic center client base primarily consisting of physical therapists and orthopedic care providers

Developed, implemented and achieved ISO-9000:2000 registered, certified system for the therapy products division

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Lemert Group Inc. – President (08/2001 – 2007/Current)

Owner/President of a privately-held engineering services firm primarily serving manufacturing operations that are in

need of both strategic and tactical engineering services focusing on new product design and development, new process

launches, automated machine and process development, new capital equipment procurement and installation, lean

manufacturing and continuous improvement assessments, facilities and workstation layouts, design-for-

manufacturing/assembly productivity improvements. Clients include medium and large scale manufacturing operations

throughout the Midwest, Canada and SW USA. More Information Available via www.lemertgroup.com

Business Engineering Inc. – Senior Industrial Engineer / Project Manager (07/1999 – 08/2001)

Reported to the owner of a privately-held engineering and industrial project management company.

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Responsible for cultivating client business relationships, proposal development and delivery. Acted as the client’s

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representative while managing several projects concurrently for all functional aspects including layout review,

vendor management, design/budgeting and cost estimating functions while maintaining targeted profit margins.

Provided optimized plant layouts and production/manufacturing line migration program to consolidate a world

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leader in the manufacture of electric lift trucks to a northwest Ohio facility of more than 700,000+ square feet.

Completed a consolidation analysis for an Indianapolis-based holding company to compare separated versus

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combined facilities for a consumer products manufacturing entity and a distribution/installation company.

Developed cellular manufacturing layouts for northeast Indiana steel fabricating company to significantly reduce

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work-in-process inventory levels by 40%.

Coordinated the design/development of an automated packing line concept for a northwest Ohio OEM parts

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repackaging firm to reduce direct labor rates by 30% and increase margins for the client firm.

Developed a phased expansion layout program for a southern Indiana-based plastics company to address both

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small tonnage injection molding and large tonnage injection molding capacity increases.

Devised and presented an automated palletizing cell for a central Indiana meat processing plant saving over 40%

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direct labor and decreased ergonomic injury potential.

Navistar International Corporation – Advanced Manufacturing Program Engineer (11/1998 – 07/1999)

Reported to Group Manager / Advanced Manufacturing Engineering – New Generation Vehicle

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Technical liaison between Design Engineering and Product Development Center for new-generation medium and

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heavy-duty truck product launch.

Developed assembly methods and specialized fixture concepts for Product Development Center review with plant

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assembly teams.

Participated in cross-functional matrix teams to assure design gate timing completion through all phases of product

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development and pre-production launch.

Mattel / Fisher-Price Toys – Senior Project Engineer-New Products (05/1995 – 10/1998)

Reported to VP of Operations/New Products of world leader toy / juvenile products / battery-powered ride-on toys.

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Responsible for all aspects of new model toy product introduction into high volume manufacturing, including profit

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margin improvement, budget costings, assembly line tooling requirements, BOM creation/maintenance, pilot

production management and outsource vendor reviews.

Responsible for implementation of concurrent assembly lines in support of pull manufacturing

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Developed material handling equipment used to reduce indirect labor by 50% across all assembly lines

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Initiated & managed multiple capital projects in excess of $500K, for plant-wide material storage requirements for

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Assembly and Finished Goods with cradle-to-grave responsibility regarding timing, cost and vendor management

Managed and supervised Manufacturing Assembly Lines with 30+ direct report unionized personnel

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Implemented Kan-Ban and Point-of-Use Warehouse concepts to reduce on-hand inventories by 70%

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Designed and developed automated production processes resulting in $300K+ annual direct labor savings

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Devised and implemented closed-loop delivery system with outside vendors to decrease scrap by 90%

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Tenneco Automotive (Walker Mfg Division) – Program Engineer-New Products (11/1993 – 05/1995)

Reported to Director of New Product Engineering of large Tier II OEM Exhaust Component Supplier

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Responsible for program management activity for new/future model introduction of prototype and full-scale

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production of exhaust components for OEM applications, including Design and Process FMEA, and PPAP

Devised and implemented design changes to FORD / Lincoln exhaust, resulting in $75K+ annualized savings

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Developed project timelines, off-site vendor audit programs for quality compliance with subcontracted processes

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Served as on-site (resident engineer) consultant for Ford Tier-1 Facility for component integration analysis and

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process improvement team, decreasing scrap by over 70%

Magnavox Electronics (Raytheon) – Senior Industrial Engineer / Systems Engineer (05/1984 – 10/1993)

Reported to Director of Operations Engineering of large of military sector telecom defense contractor

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Responsible for classical industrial engineering time study and process improvement activities

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Responsible for development and implementation of the company’s SPC systems to track production yields, defect

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analysis and troubleshooting corrective actions. Developed/delivered classroom training courses for SPC data

input and report generation for 500+ hourly and engineering support personnel.

Served as liaison between Quality and Manufacturing Engineering groups to determine SPC report criteria and

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format. Maintained both on-line and hard copy report outputs for key personnel.

Developed and conducted classroom training for over 500 hourly and engineering support personnel.

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Responsible for full development and implementation of an OSHA-compliant Material Safety Data Sheet (MSDS)

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Communications program for a multi-facility operation

EXCELLENT REFERENCES AVAILABLE UPON REQUEST

Contact this candidate