Engineer Mechanical

HUSSEIN OTHMAN

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

Home: 989-***-****, Cell :989-***-****, *********@*****.***

http://www.linkedin.com/in/husseinothman

Summary:

Mechanical engineering and project management professional with over 15 years of experience in lithium Ion polymer

Battery processing and tooling technologies, global automotive, military equipment and academic teaching. Extensive

background in lean manufacturing, assembly tooling & equipment design release, product launch and project execution to

cost, schedule and budget. Deep knowledge in manufacturing statistics and reliability techniques: RCA, SPC, DOE, Gage RR

and FMEA, DFM, DFA. Certified Statistical Apprentice Engineer and HAZWOPER. Proven ability to evaluate, develop, qualify

and optimize manufacturing processes and products. Energetic and decisive with direct, logical and friendly style.

Professional Experience:

Delta College, University Center, MI 01/2012 to present

Engineering Adjunct Faculty, teaching Strength of Materials (MT252), Hydraulics & Pneumatics (MT 220), GEO-116W-

Professional Global Awareness and Auto CAD.

Dow Kokam, Midland, MI 04/ 2010 - 12/2012

Developer and manufacturer of LIPB (Lithium Ion Polymer Battery) for transportation, defense and medical industries.

Lead Manufacturing and Production Engineer (Lithium Ion Polymer Battery SRPO, Cell Stacking and Assembly)

Providing leadership and support through daily actions, coaching and guidance to the plant teams and individuals.

Implementing business strategy and achieving plant goals including quality, EH&S, operational costs, assets utilization,

and operational reliability.

Reviewing and releasing multimillion US dollars equipment design and plant layout and resolving safety and

maintenance issues. Implementing PFMEA for new equipment, process and products.

Developing equipment specifications, process and instrument diagrams, process flow diagrams material balances, and

other key documented process knowledge. APQP process and planning including PAPP were followed as potential

supplier for the major Automotives Manufacturers.

Implementing equipment inspection and commissioning at global equipment vendors sites, South Korea and Japan.

Managing and implementing strategies to reduce variation, produce quality products, reduce inventory, reduce costs of

operations, and meet customer needs.

Deep manufacturing engineering knowledge and experience on daily basis practices including, EH&S, LOPA, RCHPA,

MSDS, OMDS, P&ID, MES (Manufacturing Execution System) SIMATIC, Micro VIEW measuring system, RCI (Root Cause

Investigation) and PFMEA.

General Motors Corporation, Warren, MI 2000 - 2010

Global manufacturer of cars and trucks.

Launched 15 future programs in several GM plants performing design release of assembly tooling & equipment, and

assembly process design with successful product launch and project execution to cost, schedule and budget . Programs

included GMX-367, GMX-365, GM211, GMX-231, GMX-020, GMX-023, GMX-024, GMX-320/GMX-322 Cadillac CTS, GMT-

745(Hummer-H3), GMT-900 Full size trucks, Lamda Crossovers (GMT-966/967/968), and Global Delta (GMX-071-Cruze).

Senior Manufacturing Project Engineer - Machinery & Equipment 2007-2010

Created assembly processes design, executed sequence of operation/deployment of equipment, continuous

improvement initiatives, and performed design concepts and design releases of new machinery/ equipment for 4

assembly plants concurrently and assumed responsibility for operational consistency, reliability and safety.

Reduced required capital investment $1.2 million by providing technical directions with math/analysis studies and

alternative solutions to GM Advanced Vehicle Development Center future programs using Team Center Enginee ring.

Lowered capital investment by $2.5 million on special assig nment using Design for manufacturing methodology to

improve product quality and enhance operation by common processes and equipment for pickup truck assembly across

all truck plants.

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Provided plant maintenance/reliability and operation groups with all troubleshooting, evaluation of equipment failures,

and technical recommendations for repairs and upgrades as needed for BCM (Body Chassis Marriage), chassis and

power train Equipment.

Developed manufacturing solutions using lean manufacturing practices and engineering techniques to ensure product

quality and performance. Prepared Manufacturing Planning Studies to establish project assumptions and costs to

establish projects budgets.

Worked with product engineering and product suppliers to develop dimensional strategies to maintain fit, form, and

function of product assemblies.

Worked with tooling vendors developing assembly fixtures to ensure dimensional repeatability of product assemblies

without impacting production flow and final throughput.

Performed continuous improvement studies for product and production improvements, product cost reductions, and

improving manufacturing and assembly efficiency using production and product statistical da ta.

Developed work cells & equipment layouts, and production methods that ensured optimal production flow. Developed

specifications and supervised the installation of tooling for new product launch and normal production.

Senior Manufacturing Project Engineer - Lead chassis/Power train 2005-2007

Planned, scheduled, conducted and coordinated the technical and management aspects of multiple programs (Pontiac

Solstice, Saturn Sky and Global Delta) for Wilmington, DE and Lordstown, OH plants.

Developed global program action plans for processes and tooling through cross-functional global teams (US, Europeans

and Asians) on-site in South Korea (US, Korean and German participation) with conisderation of Global safety standards

and DOT standards and regulations.

Led continuous improvement projects, SPS (Set Part Strategy) for cockpit assembly lines within cross functional team at

GM-Wilmington Assembly plant and reduced waste and mental/burden on operators activities that were not direct

value added and gained significant productivity and gained sequencing cost reduction annually of $427,000, increased

value-added work content by 14% and reduced headcount on cockpit line by 18% through continuous improvement

activities. Resources included, Value Stream Mapping (Current and future State Waste), Line Balance Wall and

equipment design & build skills.

Manufacturing Engineer-Future Programs Execution 2000-2004

Successfully implemented multiple full size car programs including new tooling and equipment design and build from

concept to validation, buy off and start-up within approved fund and within program timing at Oshawa, Canada plants.

Led Product Design Teams to drive common process for the new product designs, assured plant concerns were resolved

and KPC/DFM/DFA was executed appropriately.

Drove successful launch of manufacturing workstations and with direction for the design, build, installation, debug, and

validation of all workstations.

Saved $750 K, ensured safety, and reduced manpower and increased ROI in BCM stations with design and construction

of two pairs of robotics to eliminate C/O ergonomic concerns and reduce manpower cost.

Provided technical feedback with manufacturing documentation including MR (Manufacturing Requirement) and Source

of Requirement that contributed to buildable product design and provided technical ergonomic and error proofing

support to GM assembly plants and product engineering.

Radian Inc, Troy, MI 1997-2000

Supplier of mission critical special parts for military applications, now DRS Technology.

Project Engineer II:

Analyzed, designed and developed military vehicle systems components : Army Vehicle Launched Bridge (AVLB) and

launcher, M60 chassis, floating bridges (standard and improved ribbon bridge), REBS (rapidly emplaced bridge system),

DSB (dry support bridge) and bridge boat.

Extended AVLB safety and reliability and increase its capacity to handle the M1A1 Tank in the battle field by performing

corrosion study, recommending proper material specifications, destructive testing, and inspection after repairs.

Performed concept design, design analysis, 3-D model design and final design for the Palletized Loading System (PLS)

Trailer Container Kit, and AVLB system components redesign using Solidworks98, AutoCAD R14 and Pro engineer, then

created DWG files and applied GD&T, and mechanical AutoCAD Drawing with all details, assemblies, & spare parts lists.

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Contributed to US Army-TACOM review of recommendations for conversion or technical data packages from military

specifications to commercial, non-government specifications, deletion, or retention with meeting the requirement of

Mill standards, DOT, EPA and ANSI standards and regulations.

Potomac Energy Group, Alexandria, VA 1996-1997

Engineering provider for energy efficient designs for new and renovated facilities.

Mechanical Engineer:

Performed CAD Design for water supply and HVAC Systems. Prepared CAD drawings for water supply layouts in different

residential/commercial applications.

Cabrera Associates, Bethesda, MD 1993-1995

Provider of HVAC services.

Mechanical Engineer:

Designed and laid out fire suppressor/control systems for industrial facilities, including determination pump and sprinkle

head requirements. Designed and laid out drawings of HVAC systems equipment, using AutoCAD R12.

Egyptian Tank Plant (E.T.P), EG 1991-1992

Licensed manufacturer of US Army M1A1 and M60 tanks.

Manufacturing Engineer:

Analyzed and reviewed designs for best manufacturing methods and evaluated the assembly processes for the US Army

Tank M1A1 and M60 chassis systems. Supervised 7 machinists performing operations on conventional machines such as

lathe, drilling, milling, grinding, and shaper M/Cs.

Developed technical specification documents for sourcing special machines, tools and fixtures.

Performed inspections and installations of new CNC Machines/equipment.

Education:

MBA, INDIANA UNIVERSITY, Bloomington, IN 2009

MS in Mechanical Engineering, OAKLAND UNIVERSITY, Rochester, MI 2000

BS in Mechanical Engineering, ZAGAZIG UNIVERSITY, Zag azig, EG 1989

Training and Familiarization Courses:

Measurement System Analysis Overview including ANOVA, Value Stream Mapping, Statistical Engineering Apprentice,

Hybrid Electric Vehicles, 7-Dimond Process, Maintaining a harassment-Free Work environment, Electronic Bill Of Process

(eBOP) Browser Overview, Information Lifecycle Management/Managing Risk Overview, Design for Health and Safety (DHS

3.0), Design for Six Sigma(DFSS), CNC machines programming and project management and maintenance training course

(480 hrs course) on Komatsu construction equipment. Advanced Product Quality Planning (APQP), Failure Mode Effective

Analysis (FMEA), DFM, DFA, MES and Micro view measurement system. Certified HAZWOPER (Hazardous Waste Operations

and Emergency Response). Microveiw, MES, FMEA.

Computer Skills:

Software Applications:

MINITAB 16 Statistical Software, Microsoft office 2007, Ms Project, Ms Publisher 2007, Adobe Photoshop, Mat lab, MS,

MS Outlook, Lotus Notes and GM software applications such as Team Center Engineering, Team Center Community, E2,

Procurement Tracking System and PRTS.

CAD, Solid modeling and Finite Element Analysis:

AutoCAD 2010, Solid works, Pro-Engineer and ANSYS 5.6

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